Packaging for food product

ABSTRACT

A package for a food product can include an insert enclosed within a single film formable using, e.g., flow-wrapping, to enclose the food product and the insert. At least one portion of insert may be made up of an absorbent material laminated to a backing, the absorbent material adapted to absorb moisture within the package. The insert may include a base upon which the food product can be placed and two or more sides extending up from the base to contain the food product from moving in one or more directions. Fins or overlapping portions of the film may be configured on at least two edges of the single film allowing a seal to be created thereby further allowing the single film to substantially enclose the food product and the insert. Crimped seals may further be employed to completely seal the food product and the insert within the single film. One or more of the seals may be self-venting to release accumulated steam/moisture during a cooking or preparation process.

This application claims the benefit of co-pending U.S. ProvisionalApplication Ser. No. 61/838,179 (“the '179 provisional”) filed on Jun.21, 2013. This application is also a continuation-in-part of co-pendingU.S. patent application Ser. No. 14/022,137 (“the '137 application”)filed on Sep. 9, 2013 and a continuation-in-part of co-pending U.S.patent application Ser. No. 13/884,599 (“the '599 application”) filed onJul. 22, 2013. The '137 application is a continuation of U.S. patentapplication Ser. No. 12/943,769 (“the '769 application”) filed on Nov.10, 2010 and a continuation-in-part of U.S. patent application Ser. No.12/116,109 (“the '109 application) filed on May 6, 2008. The '109application claims the benefit of U.S. Provisional Application Ser. No.60/928,547 (“the '547 provisional”) filed on May 10, 2007. The '599application is a U.S. National Stage Entry of PCT Application Serial No.PCT/US11/060,001 (“the '001 PCT application”) filed on Nov. 9, 2011 anda continuation-in-part of the '769 application. The '001 PCT applicationclaims priority to U.S. Provisional Application Ser. No. 61/453,875(“the '875 provisional”) filed on Mar. 17, 2011, U.S. ProvisionalApplication Ser. No. 61/460,750 (“the '750 provisional”) filed on Feb.24, 2011, and the '769 application. The '179 provisional, the '137application, the '599 application, the '769 application, the '109application, the '547 provisional, the 001 PCT application, the '875provisional, and the '750 provisional are all hereby expresslyincorporated by reference in their entirety for all purposes. Thisapplication is also related to co-pending U.S. application Ser. No.______ (Attorney Docket No. 00052-0123) filed on even date herewith.

TECHNICAL FIELD

The present disclosure relates generally to the field of packagings forfood products, and more specifically, to packagings for food productsthat provide a more convenient means for preparing (e.g., microwavecooking, etc.) frozen or refrigerated food products for consumption byconsumers.

BACKGROUND

There are many challenges associated with providing consumers with aneasy and effective means for preparing food products using microwaveovens. Some of the long unresolved problems associated with microwavecooking include inconveniences to consumers, dryness/sogginess of foodproducts, and uneven cooking of food products, among others.

For example, many packaged food products require users to open apackaging, remove a food product, wrap the food product in a separatecovering such as paper towel, etc., and then place the wrapped foodproduct into the microwave. Such additional steps take considerable timeand are inconvenient for consumers. Further, food products often releasemoisture during microwave cooking. Without proper control of thereleased moisture, the resulting food product may be soggy, oralternatively, overly dry, and undesirable for consumption. Further yet,many food products are unevenly heated when prepared in a microwaveoven, due to improper control of moisture and/or other factors.

It would be advantageous to provide an improved packaged food productthat addresses and/or overcomes one or more of these challenges byproviding a user-friendly, easy-to-use, one-step packaged food productthat is also aesthetically pleasing in appearance. As such, variousembodiments disclosed herein provide a packaged food product that may bemicrowaveably cooked in a “one-step” fashion, and that includes, amongother features, venting and moisture absorption features to control thehumidity within the packaging and provide for an optimal moisturecontent of multi-component food products.

SUMMARY

One embodiment relates to a package. The package comprises a sheet offilm formable about a food product, and an insert configured to supportthe food product, the insert including an absorbent material. A firstedge and a second edge of the sheet of film are sealed together creatingan enclosure for the food product and the insert.

Another embodiment relates to a packaged food product. The packaged foodproduct comprises a food product and a package having an interior areacontaining the food product. The package includes a sheet of filmformable about a food product, and an insert configured to support thefood product, the insert comprising an absorbent material. A first edgeand a second edge of the sheet of film are sealed together creating anenclosure for the food product and the insert.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a packaged food product according to anexemplary embodiment.

FIG. 2 is an exploded perspective view of the packaged food product ofFIG. 1 according to an exemplary embodiment.

FIG. 3 is an exploded view of a film used in the packaged food productof FIG. 1 according to an exemplary embodiment.

FIG. 4 is a cross-section side view of the packaged food product of FIG.1 according to an exemplary embodiment.

FIG. 5 is a perspective view of a packaged food product according to analternative exemplary embodiment.

FIG. 6 is an exploded perspective view of the packaged food product ofFIG. 5 according to an exemplary embodiment.

FIG. 7 is an exploded view of a film used in the packaged food productof FIG. 5 according to an exemplary embodiment.

FIG. 8 is a cross-section side view of the packaged food product of FIG.5 according to an exemplary embodiment.

FIG. 9 is a top view of a packaged food product according to anexemplary embodiment.

FIG. 10 is a side view of the packaged food product of FIG. 9.

FIG. 11 is a top view of a packaged food product according to anexemplary embodiment.

FIG. 12 is a side view of the packaged food product of FIG. 11.

FIG. 13 is a top view of a packaged food product according to anexemplary embodiment.

FIG. 14 is a side view of the packaged food product of FIG. 13.

FIG. 15 is a top view of a packaged food product according to anexemplary embodiment.

FIG. 16 is a side view of the packaged food product of FIG. 15.

FIG. 17 is a top view of a packaged food product according to anexemplary embodiment.

FIG. 18 is a side view of the packaged food product of FIG. 17.

FIG. 19 is a top view of a packaged food product according to anexemplary embodiment.

FIG. 20 is a side view of the packaged food product of FIG. 19.

FIG. 21 is a top view of a packaged food product according to anexemplary embodiment.

FIG. 22 is a side view of the packaged food product of FIG. 21.

FIG. 23 is a top view of a packaged food product according to anexemplary embodiment.

FIG. 24 is a side view of the packaged food product of FIG. 23.

FIG. 25 is an exploded perspective view of the packaged food product ofFIG. 23.

FIG. 26 is a schematic side view of a portion of a mechanism for forminga seal for a packaged food product according to an exemplary embodiment.

FIG. 27 is perspective view of an absorbent member according to anexemplary embodiment.

FIGS. 28, 29, 30, 31A, 31B, 32A, 32B, 33, 34, 35, 36, 37A, 37B, 37C,37D, 37E, 38A, 38B, 39A, 39B, and 39C illustrate seal portions and ventportions usable with food packaging according to various exemplaryembodiments.

FIG. 40 is a perspective view of a packaged food product according toanother exemplary embodiment.

FIG. 41 is a top view of a portion of the packaged food product of FIG.40 according to an exemplary embodiment.

FIG. 42 is a side view of a portion of the packaged food product of FIG.40 according to an exemplary embodiment.

FIGS. 43A and 43B are perspective views of a package according to anexemplary embodiment.

FIGS. 44A and 44B are perspective views of a package according toanother exemplary embodiment.

FIGS. 45A and 45B are perspective views of a package according to yetanother exemplary embodiment.

FIGS. 46A and 46B are perspective views of a package according to anexemplary embodiment.

FIGS. 47A and 47B are perspective views of a package according toanother exemplary embodiment.

FIGS. 48A and 48B are perspective views of a package according toanother exemplary embodiment.

FIG. 49 is a perspective view of a package according to anotherexemplary embodiment.

FIG. 50 is a perspective view of a package according to anotherexemplary embodiment.

FIG. 51 is a perspective view of a package according to anotherexemplary embodiment.

FIG. 52 is a perspective view of a package according to anotherexemplary embodiment.

FIG. 53 is a perspective view of a package according to anotherexemplary embodiment.

FIG. 54 is a perspective view of a package according to yet anotherexemplary embodiment.

DETAILED DESCRIPTION

Referring to FIG. 1, a packaged food product 10 (e.g., a breakfastproduct, a snack product, etc.) is shown according to an exemplaryembodiment. Packaged food product 10 may be any of a variety of packagedfood products, including, but not limited to, breakfast items such asbreakfast sandwiches, etc., lunch items such as lunch sandwiches, etc.,dinner items, snack portions, and the like. As shown in FIG. 1, packagedfood product 10 includes a food product 12 provided within the interiorof packaging 14. Food product 12 may naturally contain moisture that isreleased when food product 12 is heated as a result of undergoing acooking process (e.g., microwave cooking, etc.).

Referring to FIGS. 1 and 2, according to an exemplary embodiment, foodproduct 12 is a multi-component food product and includes a plurality ofphysically separate food components shown as components 16, 18, and 20.For example, in some embodiments, food product 12 may be a breakfastsandwich, such that component 16 may be one or more pieces of biscuit,bun, or similar bread item, component 18 may be a sausage, bacon, orother meat item, and component 20 may be a cheese, sauce, or othertopping item. According to various other embodiments, food product 12may be any of a wide variety of other products, including a lunchsandwich, a snack item, etc. As such, components 16, 18, and 20 may beany of a variety of different components. According to yet otherembodiments, food product 12 may include fewer or more components thanthose shown in FIG. 2 (e.g., a single food component, two foodcomponents, four or more food components, etc.)

Further, while in some embodiments food product 12 may be intended to besold to consumers in a frozen state, in other embodiments food product12 may be intended to be sold to consumers in a refrigerated or otherstate. Thus, the embodiments herein may extend to preparing packagedfood products having food products in either a frozen or refrigeratedstate.

According to one embodiment, packaging 14 includes a first film 22(e.g., a top film or portion, a formed portion, a forming film, etc.)and a second film 24 (e.g., a second film or portion, a flat portion, anon-forming film, etc.). First and/or second films 22, 24 may be formedusing any suitable process, including a vacuum-forming process, aflow-wrapping process, etc. First film 22 includes a recess 28 (e.g., apocket, receptacle, formed portion, etc.) and a generally flat portion30 extending about recess 28. As discussed in greater detail below, inone embodiment, recess 28 is sized to provide a space, or gap 42 (e.g.,“a steam dome”) about food product 12 when food product 12 is heated ina microwave oven. First film 22 may be made from a semi-rigid filmmaterial, such as polyesters (e.g., amorphous polyethylene terephthalate(APET), polyethylene terephthalate (PETG), etc.), polyvinyl chloride(PVC), polypropylene (PP) or reduced density PP, high impactpolystyrene, and the like. As such, first film 22 may have sufficientrigidity to support food product 12 after heating and during consumptionof food product 12 (e.g., after removal of second film 24 from firstfilm 22). In other embodiments, first film 22 may be made from a varietyof other materials, including various polymer or other materials.

Referring now to FIGS. 2-4, second film 24 is a generally flat film.According to an exemplary embodiment, second film 24 includes anabsorbent layer configured to absorb at least a portion of the moisturereleased from food product 12 during heating of food product 12 (e.g.,such that liquids, etc. may travel along a path such as that indicatedby arrows 48, 49 shown in FIG. 4). For example, as shown in FIG. 3,second film 24 may include an absorbent layer 36 (e.g., a papermaterial, etc.). In one embodiment, second film 24 may be asubstantially rigid film. In other embodiments, part or all of secondfilm 24 may be a semi-rigid or flexible film.

Referring to FIG. 3, according to an exemplary embodiment, second film24 is a laminated film having different layers of material laminatedtogether. For example, as shown in FIG. 3, second film 24 may includeabsorbent layer 36 (e.g., a first layer, an absorbent layer, apaper-based layer, etc.), a middle layer 35 (e.g., an adhesive layer, asecond layer, etc.) and an outer layer 38 (e.g., a third layer, aplastic layer, an outer barrier, etc.). Layers 35, 36, 38 may belaminated (e.g., bonded, sealed, adhered, coupled, etc.) together usingany suitable methods. According to an exemplary embodiment, absorbentlayer 36 includes an inner-facing cellulose side 37 (e.g., a paper-basedside) and an outer-facing polypropylene side 39 (e.g., a polymer-basedside). Middle layer 35 may be a polyethylene adhesive or similarmaterial. Outer layer 38 may be a thermoplastic polymer such as orientedpolyethylene terephthalate (e.g., a 48 gauge OPET material, etc.) orsimilar material.

According to one embodiment, first film 22 and second film 24 are sealedby way of melting a portion of absorbent layer 36, for example, during aheat sealing process. For example, absorbent layer 36 may include aninner-facing paper-based layer that also includes polypropylene fibers.As such, first and second films 22, 24 may be heat sealed together(e.g., at seal portion 26) such that the polypropylene fibers present inabsorbent layer 36 at least partially melt during the heat sealingprocess, thereby bonding first and second films 22, 24 together. Insealing films 22 and 24, the seal is formed through the paper-basedlayer of absorbent layer 36 and with the polypropylene material. Thestrength of the seal may in some embodiments be varied by changing thepaper content of the absorbent layer, as paper fibers tend to degradethe strength of the seal.

According to one embodiment, absorbent layer 36 may be positioned suchthat absorbent layer 36 faces food product 12. According to otherembodiments, one or both of layers 35, 38 may be omitted from secondfilm 24, such that absorbent layer 36 may act as both an inner and/orouter layer for second film 24. Absorbent layer 36 is configured toabsorb moisture (e.g., heated water vapor, steam, liquids such as water,oils, grease, etc.) released from food product 12 during heating (e.g.,exposure to microwave energy) of food product 12. As such, absorbentlayer 36 acts to control the moisture content of food product 12 andprevent food product 12 from becoming too soggy (due to excessivemoisture) or too dry (due to lack of moisture). In one embodiment,absorbent layer 36 may be or include an absorbent paper material, suchas cellulose. In other embodiments, absorbent layer 36 may be or includea variety of other materials.

According to one embodiment, outer layer 38 is provided to an oppositeside of absorbent layer 36 from food product 12. Outer layer 38 acts asan outer barrier for packaging 14 and prevents unwanted moisture, gases,and other products from entering/exiting packaging 14. In oneembodiment, outer layer 38 is or includes a plastic material, such as 48gauge OPET. In other embodiments, outer layer 38 may be or include avariety of other materials.

Referring further to FIGS. 1-4, according to an exemplary embodiment,first film 22 is sealed (e.g., releasably sealed and/or resealablysealed, coupled, etc.) to second film 24 along a seal portion 26 (seeFIGS. 2 and 4) such that after heating of packaged food product 10,second film 24 may be removed from first film 22, providing consumersaccess to food product 12. Food product 12 is contained with theinterior of packaging 14 formed by first and second films 22, 24. Sealportion 26 may include any of a number of seal types, including heatsealing, adhesives, ultrasonic welding, and the like. In one embodiment,some or all of seal 26 is a non-hermetic heat seal that permits passageof fluids (e.g., steam, moisture, etc.) through seal 26. In someembodiments, seal portion 26 may extend around the entire periphery ofrecess 28 of first film 22. As discussed below, certain portions of sealportion 26 may provide a self-venting feature for packaged food product10 to provide for the release of steam during heating of food product12.

Referring now to FIG. 4, according to an exemplary embodiment, packaging14 is configured to provide a “steam dome” around portions of foodproduct 12 during heating of food product 12. For example, as shown inFIG. 4, a steam dome shown as gap or space 42 is provided between foodproduct 12 and recess 28 of first film 22. As food product 12 is heated,steam is generated and “inflates” first film 22. Space 42 provides anarea through which this steam is able to travel and continue to provideheat to food product 12 (e.g., acting as an insulator to keep the foodproduct heated longer by conducting heat) and to provide for“steam-assisted cooking,” or “steam-conductive heating.” This may serveto equilibrate the moisture within packaging 14 and ensure faster andmore even cooking of food product 12 relative to more traditional meansof microwave cooking, where steam is simply released into the interiorof the microwave oven. Further, providing space 42 also permits moistureto uniformly re-enter food product 12 to avoid over-drying of foodproduct 12, resulting in an optimal moisture content food product 12.

According to some embodiments, an anti-fog layer feature or layer 50(e.g., an anti-fog treatment or feature, etc.) may be provided as partof or on the inner surface of first film 22. Anti-fog layer 50 may be aseparate layer of material, or may be provided as an integral part offirst film 22. For example, in some embodiments, anti-fog material maybe added to a resin (e.g., as resin chips or the like) used to make oneor more films of packaging 14. Providing an anti-fog surface on firstfilm 22 eliminates and/or prevents the formation of water beads ordroplets that may otherwise form on first film 22 during heating of foodproduct 12. The anti-fog treatment is not being used to merely resistfog from appearing on the film, but to cause water to run or drain fromthe film toward the absorbent layer (i.e., to “pass” or guide watertoward the absorbent layer).

Furthermore, anti-fog layer 50 resists fogging (clouding, discoloring,etc.) of the films due to extreme or sudden temperature changes. Ananti-fog surface also maintains an aesthetically appealing visualappearance to packaged food product 10 prior to, during, and afterheating of packaged food product 10, as the packaging does not “fog up”(e.g., the packaging remains substantially transparent if a transparentpackaging material is used). According to various alternativeembodiments, an anti-fog treatment may be provided on or as a part ofone or both of first film 22 and second film 24. In one embodiment, aswater condenses on the films, the anti-fog treatment causes the water torun (e.g., drain, flow, wick, etc.) toward absorbent layer 36, where itmay remain and/or be regenerated back into steam (i.e., to “pass” orguide water toward the absorbent layer). As a result of the anti-fogtreatment, rather than water beads or droplets forming, the anti-fogtreatment reduces the surfaces tension of the film (i.e., “wetting” thefilm) such that only a fine layer of water forms (e.g., a“non-scattering” film of water) and runs down the sides of the film.

As indicated earlier, one or more vent portions may be provided as partof packaging 14. For example, seal portion 26 may provide a self-ventingfeature for packaging 14, such that one or more portions of seal portion26 (e.g., the interface between first and second films 22, 24) may beconfigured to permit a desired amount of steam or moisture to escapefrom the interior of packaging 14 during heating of food product 12(e.g., along a path indicated by arrow 46 shown in FIG. 4). In someembodiments, one or more portions of seal portion 26 may be “weakened”to provide venting of steam and/or moisture. Furthermore, first film 22may be shaped or sized to direct moisture to weakened portions of sealportion 26. For example, first film 22 may include one or more flutes(e.g., corrugations, etc.) or other features to direct moisture tospecific portions of seal portion 26.

In yet other embodiments, packaging 14 may be configured such that auser may “peel back” a portion of first film 22 from second film 24(e.g., using an “easy peel” feature) to provide an opening through whichsteam may escape from the interior of packaging 14 during heating offood product 12. For example, due to the presence of paper fibers (e.g.,non-woven, porous paper) in the films, seal portion 26 may be weakenedas the moisture (e.g., steam) escaping from the package reduces thetensile strength of the paper fibers. According to yet furtherembodiments, one or more vent portions may be configured to provideventing only upon heating of packaged food product 10 (e.g., such thatthe vent portions are otherwise substantially impermeable to liquidsand/or gases).

In some embodiments, excess moisture may be directed through specificportions of seal portion 26 to areas of packaging 14 outside of sealportion 26. For example, weakened portions or channels may be used todirect moisture to areas 21 of packaging 14 to take advantage of theabsorbency of those areas that may otherwise not by utilized. Weakenedportions of seal 26 may be provided in a variety of ways, includingnarrowing the “width” of the seal and/or reducing the “thickness” of theseal. Other ways of providing weakened areas of seal 26 may be utilizedaccording to various other embodiments. For example, various parametersof packaging machinery (e.g., pressure, temperature, dwell time, etc.)may be varied in order to provide a seal of a desired strength (e.g., a“controllable seal” formed through “fiber intervention,” where thepresence of papers fibers in the seal area can be increased or decreasedto control the strength of the seal).

As shown in FIG. 1, areas 21 may be provided in one or more of the“corners” of packaging 14. According to various alternative embodiments,the location and number of areas 21 may be varied to suit a particularpackaging configuration (e.g., variations in size, shape, etc.). In someembodiments, a scented material may be provided in areas 21, and thescented material may be activated by heat and/or moisture, such that asthe food product is prepared and moisture and/or heat travels to areas21, a scent (e.g., a fresh bread scent, a sage sausage scent, etc.) maybe activated and/or released. In one embodiment, the scented material isprovided in one or more absorbent layers of the packaging, although thescented material may be provided using different methods accordingvarious other embodiments. As indicated above, the scented material mayrelease a scent (e.g., a fresh bread scent) that is normally associatedby consumers with the food product (e.g., a bread food product) beingprepared, to enhance the consumer experience. The scent may be activatedby the contact with the moisture, the heat, air, or the like orcombinations thereof.

In combination with the absorbent features of second film 24, theventing features of packaging 14 are intended to control the humidityand/or temperature and equilibrate the moisture content (e.g., maintaina consistent, even, or desired level of moisture) within the interior ofpackaging 14 during heating of food product 12 such that, for example,the humidity level within the interior of packaging 14 remains at orbelow a predetermined level during the dynamic heating cycle of foodproduct 12. The absorbent layer acts as a “buffer” or “moisture sink” tocontrol the amount of steam/moisture within the packaging. For example,one or more venting features of packaging 14 may be configured to“delay” any venting of steam or moisture until a predeterminedtemperature, pressure, or moisture content is reached within theinterior of packaging 14. This may help to provide for faster cookingcycles and ensure a proper moisture content for food product 12 andavoid an over-dry or soggy food product.

In order to prepare the packaged food product of the present disclosure,a consumer may first simply place the packaged food product in amicrowave oven, with the “flat” portion (e.g., second film 24) facingdownward (to permit formation of the “stream dome”). The consumer maythen heat the packaged food product in the microwave oven for anappropriate amount of time (e.g., 1 minute, 2 minutes, etc.). Duringheating, steam may be released from the food product and form a “steamdome” around the exterior of the food product (e.g., inflating firstfilm 22 to define space 42). A portion of the moisture from the steammay be reabsorbed by the food product, a portion may be vented to theoutside environment, and a portion may be absorbed by the absorbentlayer of the packaging. Additional moisture (e.g., liquids such as oils,grease, etc.) released by the food product may further be absorbed bythe absorbent layer of the packaging. The food product construction; themoisture content of the food product; the size of space 42; the type,amount of, and performance of the absorbent layer; and the size,location, and performance of the vent portions are balanced to providethe proper level of moisture within packaging 14 during preparation offood product 12. Upon completion of the heating cycle, the consumer maysimply remove the packaged food product from the microwave oven, removethe flat film (e.g. second film 24) and consume the food productdirectly from the remaining packaging. If desired, a portion of thepackaging may be used to hold the food product during consumption.

Referring now to FIGS. 5-8, a packaged food product 110 (e.g., abreakfast product, a snack product, etc.) is shown according to analternative exemplary embodiment. Packaged food product 110 may besimilar to packaged food product 10 and include any of a variety ofpackaged food products, including, but not limited to, breakfast itemssuch as breakfast sandwiches, etc., lunch items such as lunchsandwiches, etc., dinner items, snack portions, and the like. As shownin FIG. 5, packaged food product 110 includes a food product 112provided within the interior of packaging 114.

Referring to FIGS. 5 and 6, according to an exemplary embodiment, foodproduct 112 is a multi-component food product and includes a pluralityof physically separate food components shown as components 116, 118, and120. For example, in some embodiments, food product 112 may be abreakfast sandwich, such that component 116 may be one or more pieces ofbiscuit, bun, or similar bread item, component 118 may be a sausage,bacon, or other meat item, and component 120 may be a cheese, sauce, orother topping item. According to various other embodiments, food product112 may be any of a wide variety of other products, including a lunchsandwich, a snack item, etc. As such, components 116, 118, and 120 maybe any of a variety of different components. According to yet otherembodiments, food product 112 may include fewer or more components thanthose shown in FIG. 6 (e.g., a single food component, two foodcomponents, four or more food components, etc.)

Further, while in some embodiments food product 112 may be intended tobe sold to consumers in a frozen state, in other embodiments foodproduct 112 may be intended to be sold to consumers in a refrigerated orother state. Thus, the embodiments herein may extend to preparingpackaged food products having food products in either a frozen orrefrigerated state.

According to one embodiment, packaging 114 includes a first film 122(e.g., a top film or portion, a formed portion, etc.) and a second film124 (e.g., a second film or portion, a flat portion, etc.). First andsecond films 122, 124 may be formed using any suitable process,including a vacuum-forming process, a flow-wrapping process, etc. Firstfilm 122 includes a recess 128 (e.g., a pocket, receptacle, formedportion, etc.) and a generally flat portion 130 extending about recess128. As discussed in greater detail below, in one embodiment, recess 128is sized to provide a space, or gap 142 (e.g., “a steam dome”) aboutfood product 112 when food product 112 is heated in a microwave oven.First film 122 may be made from a semi-rigid film material, such aspolyesters (e.g., amorphous polyethylene terephthalate (APET),polyethylene terephthalate (PETG), etc.), polyvinyl chloride (PVC),polypropylene (PP) or reduced density PP, high impact polystyrene, andthe like. As such, first film 122 may have sufficient rigidity tosupport food product 112 after heating and during consumption of foodproduct 112 (e.g., after removal of second film 124 from first film122). In other embodiments, first film 122 may be made from a variety ofother materials, including various polymer or other materials.

Referring now to FIGS. 6-8, second film 124 is a generally flat film.According to an exemplary embodiment, second film 124 includes anabsorbent layer configured to absorb at least a portion of the moisturereleased from food product 112 during heating of food product 112 (e.g.,such that liquids, etc. may travel along a path such as that indicatedby arrow 148 shown in FIG. 8). For example, as shown in FIG. 7, secondfilm 124 may include an absorbent layer 136 (e.g., a paper material,etc.). In one embodiment, second film 124 may be a substantially rigidfilm. In other embodiments, part or all of second film 124 may be asemi-rigid or flexible film.

Referring to FIG. 7, according to an exemplary embodiment, second film124 is a laminated film having different layers of material laminatedtogether. For example, as shown in FIG. 7, second film 124 may includean inner layer 134 (e.g., a first layer, a plastic layer, a perforatedlayer, etc.), absorbent layer 136 (e.g., a second layer, an absorbentlayer, a paper-based layer, etc.), and an outer layer 138 (e.g., a thirdlayer, a plastic layer, an outer barrier, etc.). Layers 134, 136, 138may be laminated (e.g., bonded, sealed, adhered, coupled, etc.) togetherusing any suitable methods.

According to one embodiment, inner layer 134 is positioned such thatinner layer 134 faces food product 112. In some embodiments, inner layer134 may include one or more perforations 140 (e.g., slits, slots,apertures, micro-perforations, etc.) that are configured to permitmoisture released from food product 112 during heating of food product112 to travel through inner layer 134 to be absorbed by absorbent layer136. Perforations 140 may be provided in any desired configuration, withany of a variety of sizes, shapes, etc., and the configuration ofperforations 140 may be based on the food product to be contained withinpackaging 114. In one embodiment, inner layer 134 may be made from afood-grade plastic material, such as polyethylene (PE). In otherembodiments, inner layer 134 may be or include a variety of othermaterials.

According to one embodiment, absorbent layer 136 may be provided betweeninner layer 134 and outer layer 138. According to other embodiments, oneor both of layers 134, 138 may be omitted from second film 124, suchthat absorbent layer 136 may also act as an inner and/or outer layer forsecond film 124. Absorbent layer 136 is configured to absorb moisture(e.g., liquids such as water, oils, grease, etc.) released from foodproduct 112 during heating of food product 112. As such, absorbent layer136 acts to control the moisture content of food product 112 and preventfood product 112 from becoming too soggy (due to excessive moisture) ortoo dry (due to a lack of moisture). In one embodiment, absorbent layer136 may be or include an absorbent paper material, such as cellulose. Inother embodiments, absorbent layer 136 may be or include a variety ofother materials. The amount of moisture absorbed by absorbent layer 136may be controlled at least in part by controlling the configuration(number, size, spacing, etc.) of perforations 140 in inner layer 134.

According to one embodiment, outer layer 138 is provided to an oppositeside of absorbent layer 136 from inner layer 134. Outer layer 138 actsas an outer barrier for packaging 114 and prevents unwanted moisture,gases, and other products from entering/exiting packaging 114. In oneembodiment, outer layer 138 is or includes a plastic material, such as48 gauge OPET. In other embodiments, outer layer 138 may be or include avariety of other materials.

Referring further to FIGS. 5-8, according to an exemplary embodiment,first film 122 is sealed (e.g., releasably sealed and/or resealablysealed, coupled, etc.) to second film 124 along a seal portion 126 (seeFIGS. 6 and 8) such that after heating of packaged food product 110,second film 124 may be removed from first film 122, providing consumersaccess to food product 112. Food product 112 is contained with theinterior of packaging 114 formed by first and second films 122, 124.Seal portion 126 may include any of a number of seal types, includingheat sealing, adhesives, ultrasonic welding, and the like. In someembodiments, seal portion 126 may extend around the entire periphery ofrecess 128 of first film 122. As discussed below, certain portions ofseal portion 126 may provide a self-venting feature for packaged foodproduct 110 to provide for the release of steam during heating of foodproduct 112.

Referring now to FIG. 8, according to an exemplary embodiment, packaging114 is configured to provide a “steam dome” around portions of foodproduct 112 during heating of food product 112. For example, as shown inFIG. 8, a steam dome shown as gap or space 142 is provided between foodproduct 112 and recess 128 of first film 122. As food product 112 isheated, steam is generated. Space 142 provides an area through whichthis steam is able to travel and continue to provide heat to foodproduct 112. This may serve to equilibrate the moisture within packaging114 and ensure faster and more even cooking of food product 112 relativeto more traditional means of microwave cooking, where steam is simplyreleased into the interior of the microwave oven. Further, providingspace 142 also permits moisture to uniformly re-enter food product 112to avoid over-drying of food product 112, resulting in an optimalmoisture content food product 112.

According to some embodiments, an anti-fog layer 150 (e.g., an anti-fogtreatment or feature, etc.) may be provided as part of the inner surfaceof first film 122. Anti-fog layer 150 may be a separate layer ofmaterial, or may be provided as an integral part of first film 122.Providing an anti-fog surface on first film 122 prevents the formationof water beads or droplets that may otherwise form on first film 122during heating of food product 112. An anti-fog surface also maintainsan aesthetically appealing visual appearance to packaged food product110 prior to, during, and after heating of packaged food product 110.According to various alternative embodiments, an anti-fog treatment maybe provided on one or both of first film 122 and second film 124.

As indicated earlier, one or more vent portions may be provided as partof packaging 114. For example, first film 122 may be provided withperforations 132 to permit a desired amount of steam to escape from theinterior of packaging 114 during heating of food product 112 (e.g.,along a path indicated by arrow 144 in FIG. 8). Perforations 132 may beprovided in any of a variety of shapes, sizes, locations, number and soon to suit a particular food product. Alternatively or in addition, sealportion 126 may provide a self-venting feature for packaging 114, suchthat one or more portions of seal portion 126 (e.g., the interfacebetween first and second films 122, 124) may be configured to permit adesired amount of steam to escape from the interior of packaging 114during heating of food product 112 (e.g., along a path indicated byarrow 146 shown in FIG. 8).

In yet other embodiments, packaging 114 may be configured such that auser may “peel back” a portion of first film 122 from second film 124(e.g., using an “easy peel” feature) to provide an opening through whichsteam may escape from the interior of packaging 114 during heating offood product 112. For example, due to the presence of paper fibers inthe films, the seal may be weakened as the moisture (e.g., steam)escaping from the package reduces the tensile strength of the paperfibers. According to yet further embodiments, one or more vent portionsmay be configured to provide venting only upon heating of packaged foodproduct 110 (e.g., such that the vent portions are otherwisesubstantially impermeable to liquids and/or gases).

It should be noted that any of the features shown in the embodimentsillustrated in FIGS. 5-8 may be used alone or in any number ofcombinations with the features shown in the embodiments illustrated inFIGS. 1-4. All such features and combinations of features are to beunderstood to be within the scope of the present disclosure.

In some embodiments, one or both of the top and bottom films may have astructure different than that disclosed herein. For example, one or moreportions of the laminated films may be heat sealed, for example, toprovide “channels” or “pathways” that direct moisture along portions ofthe films and/or to “trap” moisture in desired portions of the films.Other variations in the structure of the films disclosed herein may bemade according to various other embodiments.

Referring now to FIGS. 9-25, various alternative embodiments of packagedfood products are shown. It should be noted that the features of theembodiments shown in any of FIGS. 9-25 may be used alone or incombination with any of the other features of packaged food productsdiscussed herein, including those features discussed with respect to theembodiments shown in FIGS. 1-8. The packaging used will generally dependon the food product being contained therein and the quantity of fooditems.

Referring to FIGS. 9-10, a packaged food product 210 is shown accordingto an exemplary embodiment, and includes a packaging 214 having a firstfilm 222 and a second film 224 sealed together via a seal 226. Firstfilm 222 defines a recess, or dome 228, and made from a variety of thinplastic films or laminates. The film may be sufficiently thin andflexible to allow compaction yet protect the food product and performthe desired containment during manufacturing, transportation, heating,and handling by the consumer. Except as otherwise discussed herein, thepackaging, films, recess, and seal shown in FIGS. 9-10 may have any orall of the features discussed with respect to FIGS. 1-8 or any of theother embodiments disclosed herein. According to exemplary embodiments,the second film may be square, rectangular, circular, elliptical,elongated, or combinations thereof. As shown in FIG. 9, second film 224has a planar film having a square or rectangular perimeter. In oneembodiment, second film 224 defines a square having sides 254, 256,which may have a variety of dimensions. The sides 254, 256 of secondfilm 224 and height 266 of recess 228 may be any suitable dimension fora particular food product (not shown).

According to an exemplary embodiment, seal 226 may have a width 264 ofapproximately 4-6 mm. According to other exemplary embodiments, thewidth of the seal may be based on the desired performance of the sealduring heating of the food product. If early venting is desired, theseal width may be reduced. If increased sealing performance to inhibitventing of steam built up within the recess 228 during heating of thefood product, the width of the seal may be increased. Seal 226 maygenerally track the perimeter of second film 224, such as having agenerally square shape, and may include an angled corner portion 257that defines an area 221. Area 221 may provide a graspable tab for auser to peel apart first and second films 222, 224. According to anexemplary embodiment, a there is no bonding between first and secondfilms at area 221 to provide the graspable tab. A portion of area 221may be bonded to inhibit excessive or the appearance of inadvertentpeeling of the films (e.g., within the triangular broken line region inFIG. 9, the circular region in FIG. 40, etc.). According to an exemplaryembodiment, the base first film includes a projection (e.g., bump, etc.)extending away from the recess interior in area 221 (or 321, 421, 521,621, 721, 821, 1240, etc.) to provide a small separation between thefirst film and the second film so that the first film and the secondfilm can be easily separated by the consumer. One or more portions ofseal 226 may extend about the outermost portion of second film 224,while in other embodiments, one or more portions of seal 226 may beinset (a suitable dimension) from the outermost portions of second film224. According to other embodiments, the seal shown in FIGS. 9-10 andany of the other embodiments herein may have any of a variety of shapesor configurations (e.g., zig-zag, sinusoidal, stepped, etc.) dependingon the available space (as determined by the outer dimension and thesize of the recess/dome), desired sealing performance, and the like.Also, instead of being formed by a single annular seal, the seal may beformed by two or more annular seal rings. According to an exemplaryembodiment, first and second films may have a generally rectangularperimeter and a generally circular dome or recess 228, and be bondedtogether by linear (and substantially rectangular/square) seal 226 (withthe exception of portion 257). Such seal 226 extends along the outerarea of the films 222, 224. Alternatively, the seal (and outer peripheryof the bonded films) may be circular as shown in other embodimentsherein. Alternatively, the seal may extend from the outer periphery(whether linear or curved) inward until the first film begins itsspecial separation from the second film to form the recess.

According to an exemplary embodiment, recess 228 may have a generallycircular cross section 252 along its height (e.g., cylindrical, etc.).In some embodiments, the perimeter of recess 228 substantially abuts oris adjacent to the interior portion or edge of seal 226. For example,there may be a distance of approximately 1 to 2 mm or less betweenportions of recess 228 and seal 226. In other embodiments a greaterspace may be defined between recess 228 and seal 226.

Referring now to FIGS. 11-12, a packaged food product 310 is shownaccording to an exemplary embodiment, and includes a packaging 314having a first film 322 and a second film 324 sealed together via a seal326. First film 322 defines a recess, or dome, 328. Except as otherwisediscussed herein, the packaging, films, recess, and seal shown in FIGS.11-12 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 11, second film 324 may be a planar film having a square orrectangular perimeter. Alternatively, second film 324 may berectangular, circular, elliptical, elongated, or combinations thereof.In one embodiment, second film 324 defines a rectangle having sides 354,356 which may have a variety of dimensions. The sides 354, 356 andheight 366 of recess 328 may be any suitable dimension for a particularfood product (not shown).

According to an exemplary embodiment, seal 326 may have a width 364 ofapproximately 6-8 mm. According to other exemplary embodiments, thewidth of the seal may be based on the desired performance of the sealduring heating of the food product. If early venting is desired, theseal width may be reduced. If increased sealing performance to inhibitventing of steam built up within the recess 328 during heating of thefood product, the width of the seal may be increased. Seal 326 maygenerally track the perimeter of second film 324, such as having agenerally rectangular shape, and may include an angled corner portion357 that defines an area 321. Area 321 may provide a graspable tab for auser to peel apart first and second films 322, 324. One or more portionsof seal 326 may extend about the outermost portion of second film 324,while in other embodiments, one or more portions of seal 326 may beinset a suitable dimension from the outermost portions of second film324.

According to one embodiment, seal 326 is configured to vent at theapproximate midpoint of the longer straight sections of seal 326, suchthat the vent occurs along the side portions of the seal rather than at,for example, the corners. In some embodiments, seal 326 may vent along alongest of a plurality of sides, while in other embodiments, seal 326may vent along each of a plurality of straight-sided seal sections. Invarious embodiments, seal 326 vents at an approximate mid-point of oneor more straight-sided sections.

According to an exemplary embodiment, recess 328 may have a generallyrectangular cross section 352 with rounded corners along its height andhave a first width 360 of approximately 108.41 mm (4.268 inches) and asecond width 362 of approximately 103.86 mm (4.089 inches) while otherdimensions may be used according to other embodiments. In someembodiments, the perimeter of recess 328 substantially abuts or isadjacent to the interior portion or edge of seal 326. For example, theremay be a distance of approximately 1-2 mm or less between portions ofrecess 328 and seal 326. In other embodiments a greater space may bedefined between recess 328 and seal 326. The seal shown in FIG. 11differs from the seal shown in FIG. 9 in that the seal width is greater.For example, if an increased seal strength is desired, the width of theseal is increased, which will tend to require a reduction in thediameter of the recess 326. The shape or configuration of the recess 328is non-circular so that the recess extends along adjacent (e.g., compareFIG. 9 and FIG. 11) to the seal rather than being tangentially adjacentto the seal (i.e., provides pockets or space to receive a consumer'sfingers inserted to remove from the packaging).

Referring now to FIGS. 13-14, a packaged food product 410 is shownaccording to an exemplary embodiment, and includes a packaging 414having a first film 422 and a second film 424 sealed together via a seal426. First film 422 defines a recess, or dome, 428. Except as otherwisediscussed herein, the packaging, films, recess, and seal shown in FIGS.13-14 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 13, second film 424 may be a planar film having a square orrectangular perimeter. Alternatively, the second film may be circular,elliptical, elongated, or combinations thereof. In one embodiment,second film 424 defines a rectangle having sides 454, 456 which may beof various dimensions. The sides 454, 456, and height 466 of recess 428may be any suitable dimension for a particular food product (not shown).

In some embodiments, second film 424 may include venting portions 455.For example, venting portions 455 may include a plurality ofperforations (e.g., scores, micro-perforations, slots, slits, apertures,etc.). In one embodiment, as shown in FIG. 13, venting portions mayinclude a plurality (e.g., 2, 3, etc.) of rows of perforations, whichmay be generally parallel, or may be oriented relative to one another ina non-parallel fashion. For example, according to one embodiment,venting portions 455 comprise three parallel lines of perforationsextending across the width of second film 424. Venting portions 455 maybe produced via a laser-scoring process or any other suitable process,and may extend partially or fully through one or more layers of secondfilm 424. For example, in one embodiment, only the outer layer of secondfilm 424 is perforated. Venting portions 455 may be configured to permitsteam/moisture to release from the packaging (e.g., by expanding,rupturing, bursting, etc.) upon a predetermined pressure being reachedwithin the packaging. It should be noted that venting portions 455 maybe usable with any of the other embodiments disclosed herein.Furthermore, venting portions similar to venting portions 455 may beutilized on other portions of the packing and/or in the first film,including the top of the recess, the sides of the recess, etc.

According to an exemplary embodiment, seal 426 may have a width 464 ofapproximately 4 to 6 mm. According to other exemplary embodiments, thewidth of the seal may be based on the desired performance of the sealduring heating of the food product. If early venting is desired, theseal width may be reduced. If increased sealing performance to inhibitventing of steam built up within the recess 428 during heating of thefood product, the width of the seal may be increased. Seal 426 may havea generally square shape with rounded corners and may define an area421. Area 421 may provide a graspable tab for a user to peel apart firstand second films 422, 424. One or more portions of seal 426 may extendabout the outermost portion of second film 424, while in otherembodiments, one or more portions of seal 426 may be inset from theoutermost portions of second film 424. Area 421 for grasping by theconsumer may be provided in one or more or four of the corners of thepackaging.

According to an exemplary embodiment, recess 428 may have a generallycircular cross section 452 along its height. In some embodiments,portions of the perimeter of recess 428 substantially abut or aretangentially adjacent to the interior portion or edge of seal 426. Forexample, there may be a distance of approximately 1-2 mm or less betweenportions of recess 428 and seal 426. In other embodiments a greaterspace may be defined between recess 428 and seal 426.

Referring now to FIGS. 15-16, a packaged food product 510 is shownaccording to an exemplary embodiment, and includes a packaging 514having a first film 522 and a second film 524 sealed together via a seal526. First film 522 defines a recess, or dome, 528. Except as otherwisediscussed herein, the packaging, films, recess, and seal shown in FIGS.15-16 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 15, second film 524 may be a planar film having a square orrectangular perimeter. Alternatively, the second film may be circular,elliptical, elongated, or combinations thereof. In one embodiment,second film 524 defines a rectangle having sides 554, 556 which may havea variety of dimensions. The sides 554, 556, and height 566 of recess528 may be any suitable dimension for a particular food product (notshown).

According to one embodiment, seal 526 may have a width 564 ofapproximately 6-8 mm. According to other exemplary embodiments, thewidth of the seal may be based on the desired performance of the sealduring heating of the food product. If early venting is desired, theseal width may be reduced. If increased sealing performance to inhibitventing of steam built up within the recess 528 during heating of thefood product, the width of the seal may be increased. Seal 526 may havea generally rectangular shape with rounded corners, and may define anarea 521. Area 521 may provide a graspable tab for a user to peel apartfirst and second films 522, 524. One or more portions of seal 526 mayextend about the outermost portion of second film 524, while in otherembodiments, one or more portions of seal 526 may be inset from theoutermost portions of second film 524.

According to an exemplary embodiment, recess 528 may have a generallyrectangular cross section 552 with rounded corners along its height andhave a first width 560 having a different dimension from a second width562. Utilizing differing widths may, for example, provide clearance fora user to grasp a food product, etc. In some embodiments, the perimeterof recess 528 substantially abuts or is adjacent to the interior portionor edge of seal 526. For example, there may be a distance ofapproximately 1-2 mm or less between portions of recess 528 and seal526. In other embodiments a greater space may be defined between recess528 and seal 526.

Referring now to FIGS. 17-18, a packaged food product 610 is shownaccording to an exemplary embodiment, and includes a packaging 614having a first film 622 and a second film 624 sealed together via a seal626. First film 622 defines a recess, or dome, 628. Except as otherwisediscussed herein, the packaging, films, recess, and seal shown in FIGS.17-18 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 17, second film 624 may be a planar film having a square orrectangular perimeter. Alternatively, the second film may be circular,elliptical, elongated, or combinations thereof. In one embodiment,second film 624 defines a rectangle having sides 654, 656 which may havea variety of dimensions. The sides 654, 656, and height 666 of recess628 may be any suitable dimension for a particular food product (notshown).

According to an exemplary embodiment, seal 626 may have a width 664 ofapproximately 6 to 8 mm. According to other exemplary embodiments, thewidth of the seal may be based on the desired performance of the sealduring heating of the food product. If early venting is desired, theseal width may be reduced. If increased sealing performance to inhibitventing of steam built up within the recess 628 during heating of thefood product, the width of the seal may be increased. Seal 626 may havea generally rectangular shape with rounded corners, and may define anarea 621. Area 621 may provide a graspable tab for a user to peel apartfirst and second films 622, 624. One or more portions of seal 626 mayextend about the outermost portion of second film 624, while in otherembodiments, one or more portions of seal 626 may be inset from theoutermost portions of second film 624.

According to an exemplary embodiment, recess 628 may have a generallyrectangular cross section 652 with rounded corners along its height andhave a first width with a different dimension from a second width. Insome embodiments, the perimeter of recess 628 substantially abuts or isadjacent to the interior portion or edge of seal 626. For example, theremay be a distance of approximately 1 to 2 mm or less between portions ofrecess 628 and seal 626. In other embodiments a greater space may bedefined between recess 628 and seal 626.

According to an exemplary embodiment, a relief 668 (e.g., gap, vent,passage, weakened portion, etc.) is formed in seal 626. Relief 668 mayprovide a self-venting feature for packaging 614 by permitting a desiredamount of steam or moisture to escape from the interior of packaging 614during heating of food product 612. As shown in FIG. 17, relief 668 maybe a break or weakened area in seal 626 with a width 670 ofapproximately 6.35 mm (0.250 inches) while other dimensions may be usedaccording to other embodiments (e.g., 0.375 inches, etc.).Alternatively, a relief may be provided by having a seal with a varyingseal width.

Referring now to FIGS. 19-20, a packaged food product 710 is shownaccording to an exemplary embodiment, and includes a packaging 714having a first film 722 and a second film 724 sealed together via a seal726. First film 722 defines a recess, or dome, 728. Except as otherwisediscussed herein, the packaging, films, recess, and seal shown in FIGS.19-20 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 19, second film 724 may be a planar film having a square orrectangular perimeter. Alternatively, the second film may be circular,elliptical, elongated, or combinations thereof. In one embodiment,second film 724 defines a rectangle having sides 754, 756 which may havea variety of dimensions. The sides 754, 756, and height 766 of recess728 may be any suitable dimension for a particular food product (notshown).

According to an exemplary embodiment, seal 726 may have a width 764 ofapproximately 6-8 mm. According to other exemplary embodiments, thewidth of the seal may be based on the desired performance of the sealduring heating of the food product. If early venting is desired, theseal width may be reduced. If increased sealing performance to inhibitventing of steam built up within the recess 728 during heating of thefood product, the width of the seal may be increased. Seal 726 may havea generally rectangular shape with rounded corners, and may define anarea 721. Area 721 may provide a graspable tab for a user to peel apartfirst and second films 722, 724. One or more portions of seal 726 mayextend about the outermost portion of second film 724, while in otherembodiments, one or more portions of seal 726 may be inset from theoutermost portions of second film 724.

According to an exemplary embodiment, recess 728 may have a generallyrectangular cross section 752 with rounded corners along its height andhave a first width 760 and a second width 762 which may be a variety ofdimensions. In some embodiments, the perimeter of recess 728substantially abuts or is adjacent to the interior portion or edge ofseal 726. For example, there may be a distance of approximately 1-2 mmor less between portions of recess 728 and seal 726. In otherembodiments a greater space may be defined between recess 728 and seal726.

According to an exemplary embodiment, a relief 768 (e.g., gap, vent,passage, weakened portion, etc.) is formed in seal 626. Relief 768 mayprovide a self-venting feature for packaging 714 by permitting a desiredamount of steam or moisture to escape from the interior of packaging 714during heating of food product 712. As shown in FIG. 19, relief 768 maybe a break or weakened area in seal 726 with a width 770 ofapproximately 0.125 to 0.50 inches (e.g., 0.250 inches), while otherdimensions may be used according to other embodiments.

Referring now to FIGS. 21-22, a packaged food product 810 is shownaccording to an exemplary embodiment, and includes a packaging 814having a first film 822 and a second film 824 sealed together via a seal826. First film 822 defines a recess, or dome, 828. Except as otherwisediscussed herein, the packaging, films, recess, and seal shown in FIGS.21-22 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 21, second film 824 may be a planar film having a square orrectangular perimeter. Alternatively, the second film may be circular,elliptical, elongated, or combinations thereof. In one embodiment,second film 824 defines a rectangle having sides 854, 856 which may havea variety of dimensions. The sides 854, 856, and height 866 of recess828 may be any suitable dimension for a particular food product (notshown).

According to an exemplary embodiment, seal 826 may have a width 864 ofapproximately 6-8 mm. According to other exemplary embodiments, thewidth of the seal may be based on the desired performance of the sealduring heating of the food product. If early venting is desired, theseal width may be reduced. If increased sealing performance to inhibitventing of steam built up within the recess 828 during heating of thefood product, the width of the seal may be increased. Seal 826 may havea generally rectangular shape with rounded corners, and may define anarea 821. Area 821 may provide a graspable tab for a user to peel apartfirst and second films 822, 824. One or more portions of seal 826 mayextend about the outermost portion of second film 824, while in otherembodiments, one or more portions of seal 826 may be inset from theoutermost portions of second film 824.

According to an exemplary embodiment, recess 828 may have a generallyrectangular cross section 852 with rounded corners along its height andhave a first width 860 and a second width 862 which may have a varietyof dimensions. In some embodiments, the perimeter of recess 828substantially abuts or is adjacent to the interior portion or edge ofseal 826. For example, there may be a distance of approximately 1-2 mmor less between portions of recess 828 and seal 826. In otherembodiments a greater space may be defined between recess 828 and seal826.

According to an exemplary embodiment, multiple reliefs 868 (e.g., gaps,vents, passages, weakened portions, etc.) are formed in seal 826.Reliefs 868 may provide a self-venting feature for packaging 814 bypermitting a desired amount of steam or moisture to escape from theinterior of packaging 814 during heating of food product 812. As shownin FIG. 19, each relief 868 may be a break or weakened area in seal 826with a width 870 of approximately 6.35 mm (0.250 inches) while otherdimensions may be used according to other embodiments. For example,different reliefs 868 may have different widths based on the position ofthe relief, the type of food product, or other factors. As shown in FIG.19, multiple reliefs 868 may be generally equally distributed along seal826, while in other embodiments reliefs 868 may be otherwise distributedalong seal 826 (e.g., unequally spaced, etc.).

Referring now to FIGS. 23-25, a packaged food product 910 is shownaccording to an exemplary embodiment, and includes a packaging 914having a first film 922 and a second film 924 sealed together via a seal926. First film 922 defines a recess, or dome, 928. Recess 928 may beshaped to generally conform to a food product (e.g., a hot dog, one ortwo hamburgers/cheeseburgers, etc.). Except as otherwise discussedherein, the packaging, films, recess, and seal shown in FIGS. 23-25 mayhave any or all of the features discussed with respect to FIGS. 1-8 orany of the other embodiments disclosed herein. As shown in FIG. 23,second film 924 may be a planar film having a square or rectangularperimeter. Alternatively, the second film may be circular, elliptical,elongated, or combinations thereof. In one embodiment, second film 924defines a rectangle having a first side 954 between and a second side956 which may have a variety of dimensions. The sides 954, 956 andheight 966 of recess 928 may be any suitable dimension for a particularfood product (not shown).

According to an exemplary embodiment, seal 926 may have a width 964 ofapproximately 7-8 mm. According to other exemplary embodiments, thewidth of the seal may be based on the desired performance of the sealduring heating of the food product. If early venting is desired, theseal width may be reduced. If increased sealing performance to inhibitventing of steam built up within the recess 928 during heating of thefood product, the width of the seal may be increased. In someembodiments, seal 926 may have a generally rectangular shape. One ormore portions of seal 926 may extend about the outermost portion ofsecond film 924, while in other embodiments, one or more portions ofseal 926 may be inset from the outermost portions of second film 924.

According to an exemplary embodiment, recess 928 may have a generallyrectangular cross section 952 with rounded corners along its height andhave a first width 960 and a second width 962 which may be a variety ofdimensions. In some embodiments, the perimeter of recess 928substantially abuts or is adjacent to the interior portion or edge ofseal 926. For example, there may be a distance of approximately 1-2 mmor less between portions of recess 928 and seal 926. In otherembodiments a greater space may be defined between recess 928 and seal926.

Referring to FIG. 26, a portion of a mechanism for forming a seal suchas seal 26 for packaged food product 10 is shown schematically accordingto an exemplary embodiment. The mechanism includes a plate 1000 with arecess 1002 (e.g., gap, void, etc.). Plate 1000 is lowered onto firstfilm 22 and second film 24. Energy (e.g., heat, ultrasonic vibrations,etc.) and pressure couples first film 22 to second film 24 to form seal26. In some embodiments, a relief portion 68 is formed by the portion offirst film 22 and second film 24 aligned with recess 1002 that are notcontacted by plate 1000. The depth, width, and number of recesses 1002provided in plate 1000 may be varied to provide the appropriate numberof weakened areas of the seal (e.g., for venting, ease of opening,etc.). According to an exemplary embodiment, relief portion 68 has aheight, or depth, 1003 of approximately 0.010 inches, although thisdimension may be varied to provide a relatively stronger or weaker sealstrength at the vent portion.

According to various embodiments shown herein, an absorbent or paperlayer may be provided as part of a lamination or film (e.g., as part offirst or second films 22, 24). According to alternative embodiments,rather than or in addition to providing an absorbent layer as part of afilm or lamination, a separate absorbent member may be provided. Forexample, referring to FIG. 27, an absorbent pad or member 1004 may beprovided as a loose article within the recess (i.e., not attached to theother components of the packaging). In one embodiment, absorbent member1004 may be disk-shaped. According to other embodiments, absorbentmember may take other shapes, and may be shaped to conform to or have ashape corresponding to a packaging recess, a food product, etc.Furthermore, absorbent member 1004 may include a label 1006, which mayinclude printed text and/or graphics, etc., that may be printed ontoabsorbent member 1004 or may be provided as a separate label material.When the absorbent member also serves as a label, the absorbent membermay be coupled to the first film 222 and/or the second film 224.

As shown in various embodiments herein, the inner perimeter of therecess or dome of the packaging may extend from adjacent to or proximateto the seal portion. In other embodiments, a space may be providedbetween the recess and the seal along all or a portion of the peripheryof the recess. The shape of the seal may also be varied to suitparticular applications. Utilizing a generally square or rectangularseal may provide increased seal strength (e.g., by increasing thedistance from the seal to the recess). Furthermore, the size and shapeof the recess may be any of a wide variety. For example, providing arecess having differing width/length dimensions may provide room forusers to grasp food products with fingers, utilize utensils, etc.

Referring now to FIGS. 28-39C, various schematic representations areprovided according to exemplary embodiments to illustrate different sealportions (e.g., portions where the first and second films are sealedtogether) and vent portions (e.g., portions having a relatively weakerseal between the first and second films, or alternatively, portions voidof a seal between the first and second films). According to any of thevarious embodiments disclosed herein, vent portions may provide ventingof steam/pressure through the interface of the first and second films ina variety of ways. For example, a width of a seal may be narrowed toprovide a vent portion having a relatively weaker seal strength.Alternatively, the strength of the seal may be lessened by providing a“relief” in a seal bar used to form the seal (see e.g., FIG. 26),thereby forming a vent portion having a relatively weaker seal strength.Further, a wide variety of dimensions may be varied (e.g., the lengthand/or width of a narrowed portion of seal, the length, width, and/ordepth of a relief formed in a seal bar, etc.) to vary the strength of aseal at a seal portion. Such variation in the seal configuration,dimensions, and geometry are provided in exemplary embodiments becausethe packaging uses polymer film layers that seal through an absorbentlayer (which is possible due to polymer fibers in the absorbent layer).

It should also be noted that the sealing and venting features disclosedherein may be used with any suitable recess, or “dome,” that receivesfood products, including domes having a generally circularcross-section, square cross-section, rectangular cross-section,square/rectangular with rounded corners cross-section, multi-sidedpolygonal cross-section, etc. as shown in the FIGURES herein. Further,the seal portions may be spaced apart from (e.g., in the case of asquare/rectangular seal around a circular dome) or adjacent to (in thecase of a circular seal around a circular dome) the dome. All suchcombinations of domes, seal portions, and vent portions are within thescope of the present disclosure. Greater details of varioussealing/venting combinations are provided below with respect to FIGS.28-39C. It should be understood that unless otherwise provided herein,the sealing/venting features shown in FIGS. 28-39C may be included as apart of any of the food packages shown herein and/or utilized with anyother features disclosed herein. For example, any of the seals may beused with a generally circular cross section dome (see FIG. 17) or witha square/rectangular with rounded corners cross section dome (see FIG.19).

According to various embodiments, the seal portions may have variouswidths. For example, according to one embodiment, when using a generallycircular dome, the seal portion may have a width of approximately 5 mm;when using a square/rectangle with rounded edges dome, the seal portionmay have a width of approximately 7 mm; and when using a seal portionwith inner/outer seal portions (see e.g. FIG. 37, FIG. 39, and the otherFIGURES herein) the inner and outer seal portions may each have a widthof approximately 2 mm and be spaced approximately 3 mm apart, for atotal seal portion width of 7 mm. According to various otherembodiments, other widths for the various seal portions may be used.

Referring now to FIG. 28, a seal portion 990 is shown according to anexemplary embodiment and includes a number of vent portions 992. Asshown in FIG. 28, seal portion 990 may be circular, orsquare/rectangular with rounded corners. In one embodiment, seal portion990 may include three vent portions 992 on opposing sides of sealportion 990 (e.g., in the case of generally square/rectangle seal)although according to various other embodiments, more or fewer ventportions may be utilized, and the size, spacing, placement, and shape ofvent portions 992 may be varied to suit a particular application. In oneembodiment, vent portions 992 have a length of approximately 0.250inches, although other dimensions may be used to provide a larger orsmaller vent portion (e.g., 0.125 inches, 0.375 inches, 0.500 inches,etc.).

Referring to FIG. 29, a seal portion 1010 is shown according to anexemplary embodiment. As shown in FIG. 29, a portion of seal portion1010 is formed by straight sides joined perpendicularly, and has longestsides 1014, 1016. Vent portion 1012 may be formed in one or both ofsides 1014, 1016 and may have a length of 0.375 inches. Furthermore, insome embodiments, additional sides may have further vent portions. Forexample, referring to FIG. 30, a seal portion 1020 is shown according toan exemplary embodiment and includes four vent portions 1022, eachhaving a length of 0.250 inches.

Referring to FIGS. 31A-32B, a seal portion 1030 has a number of ventportions 1032. Vent portion 1032 is formed by a portion of seal portion1030 having a reduced width (e.g., forming a recess, or notch, in sealportion 1030). The notch may provide a weakened seal area or a void inthe seal portion. While vent portion 1032 is shown formed by a generallycurved, or chamfered, notch in seal portion 1030, vent portion 1032 maybe formed with other shapes (e.g., V-shapes, U-shapes, rectangularshapes, etc.). In some embodiments, vent portions 1032 may be formed byreducing a seal width from 7 mm to 3 mm, or alternatively, from 5 mm to2 mm, and the notch, or recess, may have a width of approximately 0.187inches on the inner edge of the seal portion, as shown in FIG. 31B. Sealportion 1030 may be generally circular, or alternativesquare/rectangular with rounded corners. Further, a number (e.g., 3, 4,etc.) of vents may be provided on opposing sides of seal portion 1030(e.g., on opposite sides of a rectangular seal, etc.). According toother embodiments, vent portions 1032 may be provided around the entireperimeter of seal portion 1030, and may be spaced at regular orirregular intervals. Referring to FIG. 32, a straight-sided seal portion1040 may include one or more vent portions 1042 on one or more of eachof the sides (e.g., on the four longer of the five straight sides, onthe two longest sides, etc.). Vent portions 1042 may be formed in asimilar manner to vent portions 1032 shown in FIG. 31.

Referring now to FIG. 33, a seal portion 1050 is shown according to anexemplary embodiment and is a straight-sided seal having a shortest side1059, two intermediate length sides 1056, and two long sides 1058. Ventportions 1052 may be provided on each of the intermediate sides 1056 andlong sides 1058. According to one embodiment, vent portions 1052 areprovided at the midpoint along the length of each of sides 1056, 1058.Furthermore, additional vent portions 1054 may be provided, for example,equally spaced to either side of vent portions 1052 on long sides 1058.Alternatively, additional vents could be provided on either side of ventportions 1052 on intermediate sides 1056. In one embodiment, ventportions 1052, 1054 have a length of approximately 0.25 inches.

Referring to FIG. 34, a seal portion 1060 is shown according to anexemplary embodiment. As shown in FIG. 34, the entire portions of thefirst and second films (except the recess, or dome portion), may besealed together except for a peelable corner portion 1064. Vent portions1062 may be provided at four equally spaced locations about the dome(e.g., a circular cross-section dome), although more or fewer ventportions may be provided and the vent portions may be equally orunequally spaced about the perimeter of the dome. According to oneembodiment, each vent portion tapers from a first width 1066 adjacentthe dome to a second width 1068 at the edge of the packaging. In oneembodiment, first width 1066 may be about twice second width 1068 (e.g.,providing a 2:1 ratio), although other dimensions (e.g., a 3:2 ratio,etc.) may be used according to various alternative embodiments. Forexample, first width 1066 may be approximately 0.5 inches, and secondwidth 1068 may be approximately 0.25 inches. Alternatively, first width1066 may be approximately 0.375 inches and second width 1068 may beapproximately 0.25 inches. In some embodiments, vent portions 1062 areprovided at the narrowest portions of seal portion 1060 (e.g., at theapproximate midpoint along each of the straight edges of the first andsecond films). FIG. 35 is similar to FIG. 34, except that seal portion1070 shown in FIG. 35 has no venting such as vent portions 1062 shown inFIG. 34.

Referring now to FIG. 36, a seal portion 1080 is shown according to anexemplary embodiment and is similar to seal portion 1060 shown in FIG.34 except that vent portions 1082 are straight-sided vent portionsrather than tapered. The length (e.g., 0.25 in., 0.375 in., 0.50 in.,etc.) of vent portions 1082 may be varied to suit a particularapplication, and the number (e.g., more or less than four) and spacing(regular-spaced, irregular-spaced) of vent portions may be varied.

Referring to FIG. 37A-37E, a seal portion 1090 is shown according to anexemplary embodiment and includes an inner seal portion 1091 and anouter seal portion 1093 in a generally parallel fashion. According toone embodiment, inner and outer seal portions 1091, 1093 may beconcentric circles, although according to various other embodiments,inner and outer seal portions 1091, 1093 may take any suitable shape,with inner seal portion running along the inside of outer seal portion1093. According to one embodiment, seal portions 1091, 1093 eachincludes 4 vent portions 1092 equally spaced about seal portions 1091,1093. In some embodiments, vent portions 1092 on inner seal portion 1091may be staggered apart from (e.g., located midway between) vent portions1092 on outer seal portion 1093. According to other embodiments, thevent portions on seal portions 1091, 1093 may be generally aligned (FIG.37E), or offset in a different fashion than as shown in FIG. 37A. FIG.37B shows a profile of inner and outer seal portions 1091,1093 accordingto an exemplary embodiment.

While as shown in FIG. 37A each of inner and outer seal portions 1091,1093 may include 4 vent portions, more or fewer vent portions may beutilized. For example, in some embodiments, six vent portions 1092 maybe provided on each of seal portions 1091, 1093, and the vent portionsmay be staggered (see FIG. 37C). In other embodiments, differing numbersof vent portions 1092 may be provided on each of inner seal portion 1091and outer seal portion 1093. For example, inner seal portion 1091 mayinclude six vent portions 1092 and outer seal portion 1093 may include 4vent portions 1092, and one or more “pairs” of vent portions on sealportions 1091. 1093 may be staggered and/or aligned (see FIG. 37E).

Referring to FIGS. 38A-38B, a seal portion 1100 is shown according to anexemplary embodiment, and includes a number of vent portions 1102. Sealportion 1100 covers the entire interface between the first and secondfilms except a peelable portion 1104 at one or more corners. As shown inFIG. 38, four vent portions 1102 are provided in the form of narrowedportions of seal portion 1100 (e.g., in a manner similar to ventportions 1032 shown in FIG. 31). The size, shape, number, and spacing ofvent portions 1102 may be varied according to various alternativeembodiments. As shown in FIG. 38B, each vent portion 1102 may be formedby providing a chamfered notch or recess that reduces the width of aseal from, for example, 5 mm to 2 mm and has a width at the inner edgeof the seal portion of approximately 0.5 inches. As noted herein, thenotch may be provided by a relatively weaker seal portion, oralternatively, a void in the seal portion.

Referring to FIG. 39A, a seal portion 1110 is shown according to anexemplary embodiment, and includes an inner seal portion 1111 and anouter seal portion 1113. Inner and outer seal portions 1111 and 1113generally include straight sides that run along each other in agenerally parallel fashion. As shown in FIG. 39A, each of seal portions1111, 1113 includes four seal portions 1112 (e.g., one vent portion oneach intermediate length side, and one vent portion on each long side)provided at the midpoint of sides of seal portion 1110. The size,number, placement, and spacing of vent portions 1112 may be variedaccording to various alternative embodiments. In one embodiment, innerand outer seal portions 1111, 1113 may each include six vent portions1112 (see FIG. 39B). For example, inner and outer seal portions 1111 and1113 may include a single vent portion 1112 on each of the intermediatelength sides and two vent portions 1112 on each of the longer lengthsides. The vent portions 1112 may be staggered relative to each otherand may be positioned based on a desired venting configuration (e.g.,with the vents on the long sides of inner seal 1111 staggered to theinside of the vent portions 1112 on the long sides of outer seal portion1113, etc.,). Furthermore, inner and outer seal portions 1111 and 1113may have differing numbers of vent portions (e.g., inner seal portion1111 may have six vent portions 1112 while outer seal portion may havefour vent portions 1112, vice-versa, etc.) as shown in FIG. 39C.

Referring now to FIGS. 40-42, a packaged food product 1210 is shownaccording to an exemplary embodiment. Product 1210 includes a packaging1214 configured to hold a food product (not shown). Packaged foodproduct 1210 and packaging 1214 may include one or more of the featuresdescribed in the various other embodiments described herein. Accordingto an exemplary embodiment, packaging 1214 includes a top, or upperportion 1224 (e.g., a flat film, etc.) and a bottom, or lower portion1222 (e.g., a formed member, receptacle cup, etc.).

Top portion 1224 is sealed to bottom portion 1222 via a seal portion1226 to form an interior 1228. A food product is sealed within interior1228 via top and bottom portions 1224, 1222 and seal portion 1226. Thefood product may be any of a variety of food products intended to beheated in a microwave oven, including any of the food products describedwith respect to food product 12 discussed herein, such as hamburgers,hot dogs, hot dogs wrapped in dough, sandwiches, etc.

Top film 1224 may be a generally flat film similar to film 24. In someembodiments, film 1224 may be a flexible film, while according to otherembodiments, film 1224 may be all or partially made up of semi-flexibleor rigid portions. Film 1224 may generally be sized and shaped such thatthe outer periphery of top film 1224 is generally aligned with the outerperiphery of bottom film 1222. Top film 1224 may form a pull tab 1240configured to enable a user to peal top film 1224 away from bottom film1222. According to some embodiments, top film 1224 may be made of alamination of materials, including an absorbent layer, various sealants,and/or polymer films. For example, the film may be a co-extrudedlaminate of a barrier film (e.g., ethylene vinyl alcohol copolymer orEVOH, etc.), a sealant (e.g., ionomer, polyethylene, ethyl vinyl acetateor EVA, etc.), and structural layers (e.g., nylon, polypropylene, etc.).The non-conforming or base film includes oriented polyethyleneterephthalate (OPET) layer, adhesive (e.g., polyethylene), and a wovenor a non-woven absorbent material layer (e.g., cellulose andpolypropylene).

Bottom film 1222 may be formed using any suitable process, includingvacuum-forming, flow-wrapping, etc. Bottom film 1222 forms interior 1228and includes a flat portion 1230 (e.g., a rim, flange, lip, etc.)extending about the upper periphery of interior 1228. The shape and sizeof interior 1228 and/or flat portion 1230 may be varied to provide adesired packaging type and/or to accommodate a specific food product. Insome embodiments, the outer periphery of flat portion 1230 forms arectangular, or square shape, while in other embodiments, other shapesmay be formed, including circular, oval, irregular, etc. For example, asshown in FIGS. 40-42, interior 1228 may have a generally rectangularcross-section except that one corner is instead rounded, providing ashape having two substantially straight sides and one curved side (e.g.,a curved “side” formed by two substantially straight portions joined bya curved portion). According to exemplary embodiments, the curved sidehelps to focus the pulling force on the sealant by the consumer whenseparating the films due the reduced area that initially absorbs theforce when the pulling/separation begins. The depth of interior 1228 maybe varied to provide a packaging having a suitable depth for aparticular food product. The curved side may conform to a food product,form a space for a pull-tab, etc.

Bottom film 1222 may be made of any suitable material, including anumber of flexible, semi-rigid, or rigid polymers, including any of thematerials described herein in connection with film 22. In someembodiments, bottom film 1222 may be semi-rigid and have sufficientrigidity to maintain its shape and support the food product during sale,preparation, and consumption of the food product. In some embodiments,bottom film 1222 is made from a lamination of materials, includingvarious sealants and/or polymer films.

According to an exemplary embodiment, seal portion 1226 is configured toprovide a gas and/or moisture seal between interior 1228 and theexterior environment. Seal 1226 may be formed in a variety of ways,including heat sealing the top and bottom films together, weldingoperations, using one or more adhesives, or combinations thereof. Insome embodiments, seal portion 1226 is formed by melting the top andbottom films together using an appropriate heat, pressure, etc.

According to an exemplary embodiment, seal 1226 is configured to provideventing features to the packaging to release gas, steam, and/or moisturefrom interior 1228 during preparation (e.g., heating) of the foodproduct (e.g., by way of a microwave oven). For example, one or moreportions of seal 1226 may be configured to provide a “vent” to permitthe release of steam, moisture, etc.

In one embodiment, seal 1226 is configured such that seal 1226 vents atthe approximate midpoints along straight sections of seal 1226. Forexample, referring to FIG. 41, seal 1226 may include two relativelylonger straight sections 1232, 1234, and two relatively shorter straightsections 1236, 1238. Upon heating of product 1210, seal 1226 may beconfigured to vent at the approximate midpoints of sections 1232, 1234(e.g., the longer straight sides). In some embodiments, a weakenedportion of seal 1226 may be provided at one or more locations about seal1226 to promote venting, while in other embodiments, seal 1226 may havea generally uniform size, shape, and seal strength about its periphery,and seal 1226 may tend to rupture at desired locations due to thegeometry of seal 1226 (e.g., by providing an elongated packaging havingcorresponding elongated straight seal portions configured to providevents at their approximate midpoints).

While seal 1226 is shown in FIG. 41 to have two relatively longersections (sections 1232, 1234), accordingly to other embodiments, otherconfigurations and/or geometries may be used to control the venting ofproduct 10. For example, seal 1226 may be generally square, multi-sided,etc., and the venting may be directed through the seal by providing oneor more relatively longer straight sections (one or more of whichprovide venting at an approximate mid-section of the straight portion).As such, one or more vent portions may be provided by the approximatemid-sections of various straight-sided sections of the seal withouthaving to provide any weakened portions of seal. In yet furtherembodiments, seal 1226 may be configured to vent at discreet locationsalong one or more sections of the vent (e.g., by weakened portions,etc.) as discussed with respect to various other embodiments disclosedherein.

In some embodiments, seal 1226 may extend about the upper periphery ofinterior 1228, while in other embodiments, one or more positions of seal1226 may be offset or spaced apart from seal 1226. For example,referring back to FIGS. 9-11, a straight-sided (e.g., square, polygonal,etc.) seal may be provided about a circular or rounded interior, suchthat the seal tends to vent at the midpoint of the longer sides ratherthan, for example, at the corners of the seal. Further, while seal 1226is shown as having a generally constant width 1242 about interior 1228,according to other embodiments the width of seal 1226 may be varied atone or more sections along its length.

Referring now to FIGS. 43-45, a package or packaging for, e.g., a foodproduct, is shown according to various exemplary embodiments, where thepackaging may be a “single” film (e.g., sheet or length of film), orother material configured or formed by, e.g., a flow-wrapping process,similar, for example, to that described previously with respect tobottom film 1222. In particular, FIG. 43A illustrates a film 1302, whichmay be a section of a film roll that can be fed via a film feed assemblyonto a former or forming area in a flow-wrapping apparatus or system inthe direction of arrow 1305, for example. Film 1302 may includelaminated areas 1304 along at least two edges of the film 1302. Forexample, laminated areas 1304 may be made up of a lamination ofmaterials, by laminating an absorbent or paper layer to film 1302, aspreviously discussed for, e.g., absorbing moisture during a food productpreparation or cooking process, as also previously described,controlling the amount of steam/moisture within the packaging, etc. Itshould be noted that the laminated areas 1304 may include or be made upof other materials, such as various sealants, polymer films, etc.,whereas the film 1302 itself may be any suitable material, such asflexible film, semi-rigid polymers, etc. Additionally, film 1302 mayinclude a non-laminated and/or “clear” area 1306 through which a foodproduct packaged in the packaging may be viewed, as also previouslydescribed. The non-laminated/clear area 1306 may have an anti-fogfeature or layer provided thereon as part of the inner surface of thenon-laminated/clear area 1306. Further still, the laminated areas 1304and the non-laminated/clear area 1306 can be configured to have shapesother than the “strip-like” shapes illustrated in FIGS. 43A and 43B.

FIG. 43B illustrates film 1302 as it may be formed into a cylindricaltube or otherwise encompassing shape configured to enclose a foodproduct. That is, film 1302 may progress through the flow-wrappingapparatus or system in the direction of arrow 1305. In forming film1302, a fin seal may be created by forming fins 1308 on either side offilm 1302, and sealing fins 1308 together. Fins 1308 can be mated andsealed to form a fin seal by, e.g., pulling film 1302 (as well as a foodproduct enclosed therein) through the aforementioned former or formingarea and allowing fin seal wheels of the flow-wrapping apparatus ofsystem to seal fins 1308 by way of heat and pressure, or a cold seal,etc.

As can be appreciated, after forming film 1302 about the food product,two open ends can result, which may be crimped to fully seal the foodproduct within film 1302. It should be noted that the resulting fin sealcan be folded down or against film 1302, allowing the food product toultimately sit or rest on laminated areas 1304, and seen by a consumerthrough the non-laminated/clear area 1306. That is, and for example, thefood product can be laid or positioned upside down on film 1302 as it isformed, and the packaging including the food product may be “turnedover” after forming and crimping is complete for presentation.Additionally, and during a food product preparation or cooking process,the non-laminated/clear area 1306 may act as a steam dome, as previouslydescribed. Moreover, the resulting fin seal and/or one or both crimpedends can be created in such a manner that allows for self-venting, aspreviously described.

FIGS. 44A and 44B illustrate a package in accordance with anotherexemplary embodiment, where the packaging may again be a single film(e.g., sheet or length of film) or other material configured or formedby, e.g., a flow-wrapping process, similar, for example, to thatdescribed previously with respect to bottom film 1222. In particular,FIG. 44A illustrates a film 1310, which may be a section of a film rollthat can be fed via a film feed assembly onto a former or forming areain a flow-wrapping apparatus or system in the direction of arrow 1315,for example. Film 1310 may be any suitable material, such as flexiblefilm, semi-rigid polymers, etc. Film 1310 may include a laminated area1312 located substantially in a center area of film 1310, which caninclude an absorbent or paper layer laminated to film 1310 for absorbingmoisture during a food product preparation or cooking process,controlling the amount of steam/moisture within the food productpackaging, etc. It should be noted that the laminated area 1312 mayinclude or be made up of other materials, such as various sealants,polymer films, etc. Film 1310 may further include non-laminated and/orclear areas 1314 that can border either side of the laminated area 1312through which a food product packaged in the packaging may be viewed,and which may act as a steam dome. The non-laminated/clear areas 1314may have an anti-fog feature or layer provided thereon as part of theinner surface of the non-laminated/clear areas 1314. It should be notedthat the laminated area 1312 and the non-laminated/clear areas 1314 canbe configured to have shapes other than the “strip-like” shapesillustrated in FIGS. 44A and 44B.

FIG. 44B illustrates film 1310 as it may be formed into a cylindricaltube or otherwise encompassing shape configured to enclose a foodproduct, as it progresses through the flow-wrapping apparatus or systemin the direction of arrow 1315. Similar to the embodiment illustrated inFIGS. 43A and 43B, a fin seal may be created by forming fins 1316 oneither side of film 1310, and sealing fins 1316 together. Fins 1316 canbe mated and sealed to form a fin seal by, e.g., pulling film 1310 (aswell as a food product enclosed therein) through the aforementionedformer or forming area and allowing fin seal wheels of the flow-wrappingapparatus of system to seal fins 1316 by way of heat and pressure, or acold seal, etc.

As can be appreciated, after forming film 1310 about the food product,the resulting open ends can be crimped to fully seal the food productwithin film 1310. It should be noted that the resulting fin seal can befolded down or against film 1310. In this particular embodiment, thefood product may rest on laminated area 1312 (without needing to beturned over), and seen by a consumer through the non-laminated/clearareas 1314, which may again, act as a steam dome, as previouslydescribed. Moreover, the resulting fin seal and/or one or both crimpedends can be created in such a manner that allows for self-venting.

FIGS. 45A and 45B illustrate a package in accordance with still anotherexemplary embodiment, where the packaging may again be a single film(e.g., sheet or length of film) or other material configured or formedby, e.g., a flow-wrapping process, similar, for example, to thatdescribed previously with respect to bottom film 1222. In particular,FIG. 45A illustrates a film 1318, which may be a section of a film rollthat can be fed via a film feed assembly onto a former or forming areain a flow-wrapping apparatus or system in the direction of arrow 1320,for example. Film 1318 may be any suitable material, such as flexiblefilm, semi-rigid polymers, etc. Film 1318 may be laminated in itsentirety, such that film 1318 can include an absorbent or paper layerlaminated thereon for absorbing moisture during a food productpreparation or cooking process, controlling the amount of steam/moisturewithin the food product packaging, etc., and/or other materials, such asvarious sealants, polymer films, etc.

FIG. 45B illustrates film 1318 as it may be formed into a cylindricaltube or otherwise encompassing shape configured to enclose a foodproduct, as it progresses through the flow-wrapping apparatus or systemin the direction of arrow 1320. Similar to the embodiments illustratedin FIGS. 43-44, a fin seal may be created by forming fins 1322 on eitherside of film 1318, and sealing fins 1322 together. Fins 1322 can bemated and sealed to form a fin seal by, e.g., pulling film 1318 (as wellas a food product enclosed therein) through the aforementioned former orforming area and allowing fin seal wheels of the flow-wrapping apparatusof system to seal fins 1322 by way of heat and pressure, or a cold seal,etc.

As can be appreciated, after forming film 1318 about the food product,the resulting open ends can be crimped to fully seal the food productwithin film 1318. It should be noted that the resulting fin seal can befolded down or against film 1318. In this particular embodiment, thefood product may rest on either the fin seal side of film 1318 or on theopposite side of film 1318. Moreover, the resulting fin seal and/or oneor both crimped ends can be created in such a manner that allows forself-venting. The embodiment illustrated in FIGS. 45A and 45B may beparticularly applicable to food products and/or food product preparationor cooking processes that require a greater level of moisture or steamabsorbency.

It should be noted that the various embodiments illustrated in FIGS.43-45 and described herein, and implemented utilizing a single, e.g.,flow-wrap film, may incorporate one or more features of otherembodiments illustrated in FIGS. 1-42 and described above.

Referring now to FIGS. 46-54, a package or packaging for, e.g., a foodproduct, is shown according to various exemplary embodiments, where thepackaging may be an insert contained within a “single” film (e.g., sheetor length of film), or other material configured or formed by, e.g., aflow-wrapping process, similar, for example, to that describedpreviously with respect to bottom film 1222 or films 1302, 1310 and1318. In particular, FIGS. 46A and 46B illustrate an insert 1402 to becontained within a film 1420. The insert 1402 may include an absorbentlayer, a paper layer, or an absorbent layer laminated on a paper backing(or plastic backing) The insert 1402 may include a base 1415, a firstside 1410-1 and a second side 1410-2. The base 1415 may be designed tosupport the bottom of a food product while the sides 1410 may extend up(e.g., perpendicular) from the base 1415 to contain the food product,e.g., prevent motion, from moving in a direction perpendicular to thesides 1410. Having only two sides 1410 may allow the food product to beeasily slid out of an open end of the package to fully remove the foodproduct or, alternatively, may allow the food product to be slid outgradually while one is eating the food product, and while the insert isstill absorbing moisture. The insert 1402 may also provide additionalstability to the package. In some embodiments, the sides 1410 may beomitted.

The film 1420 may be a section of a film roll that can be fed via a filmfeed assembly onto a former or forming area in a flow-wrapping apparatusor system. Film 1420 may or may not include laminated areas, not shown,such as the laminated areas 1304, 1312 or be entirely laminated such asthe film 1318 described above. However, these laminated areas may beomitted since the insert 1402 may be sufficient to absorb any moisturegiven off by the food product during heating.

The insert 1402 may be made up of a lamination of materials, bylaminating an absorbent layer on a paper backing layer, e.g., forabsorbing moisture during a food product preparation or cooking process,or for controlling the amount of steam/moisture within the packaging,etc. It should be noted that the insert 1402 may include or be made upof other materials, such as various sealants, polymer films, etc.,whereas the film 1420 itself may be any suitable material, such asflexible film, semi-rigid polymers, etc. Additionally, insert 1402 mayinclude a plastic backing layer such as a thermoplastic polymer such asoriented polyethylene terephthalate (e.g., a 48 gauge OPET material,etc.) or similar material with an absorbent layer laminated thereon. Forexample, the insert 1402 may include an absorbent layer comprising 60%cellulose and 40% polypropylene laminated on a 48 gauge OPET material.Multiple layers of such plastic backing layers may be used for addedrigidity.

As illustrated in FIG. 46B, the insert 1402, and the food product, notshown, may be inserted, e.g., using a horizontal form fill sealapparatus, into film 1420. The film 1420 may be formed into acylindrical tube or otherwise encompassing shape configured to encloseboth the insert 1402 and the food product. That is, film 1420 and theinsert 1402 may progress through the flow-wrapping apparatus or systemin the direction of arrow 1430. In forming film 1420, a fin seal may becreated by forming fins 1422 on either side of film 1420, and sealingfins 1422 together. Fins 1422 can be mated and sealed to form a fin sealby, e.g., pulling film 1420 and insert 1402 (as well as a food productsupported and enclosed therein) through the aforementioned former orforming area and allowing fin seal wheels of the flow-wrapping apparatusof system to seal fins 1422 by way of heat and pressure, or a cold seal,etc.

As discussed above, after forming film 1420 about the insert 1402 andfood product, two open ends can result, which may be crimped to fullyseal the food product within film 1420 and supported by the insert 1402.It should be noted that the resulting fin seal can be folded down oragainst film 1420, allowing the insert 1402 to ultimately sit or rest ona bottom of film 1420. The resulting fin seal and/or one or both crimpedends can be created in such a manner that allows for self-venting, aspreviously described. The resulting package could be moisture and/or gasimpermeable.

FIGS. 47A and 47B illustrate an insert 1502 to be contained within afilm 1530. The insert 1502 may include an absorbent layer, a paperlayer, or an absorbent layer laminated on a paper backing (or plasticbacking) The insert 1502 may include a base 1520, a first long side1510-1, a second long side 1510-2, a first short side 1515-1 and asecond short side 1515-2. The base 1520 may be designed to support thebottom portion of a food product while the sides 1510 and 1515 mayextend upward (e.g., perpendicular) from the base 1520 to contain thefood product, e.g., prevent motion in two directions perpendicular tothe long sides 1510 as well as the short sides 1515. Having both thelong sides 1510 and the short sides 1515 may allow both the food productand the insert 1502 to be easily slid out of an open end of the packageto fully remove both the insert 1502 and the food product. In this way,the insert 1502 may also provide additional stability to both thepackage, while within the package, and to the food product when theinsert 1502 and food product are removed from the package.

The film 1530 may be a section of a film roll that can be fed via a filmfeed assembly onto a former or forming area in a flow-wrapping apparatusor system. Film 1530 may or may not include laminated areas, not shown,such as the laminated areas 1304, 1312 or be entirely laminated such asthe film 1318 described above. However, these laminated areas may beomitted since the insert 1502 may be sufficient to absorb any moisturegiven off by the food product during heating.

The insert 1502 may be made up of a lamination of materials, bylaminating an absorbent layer on a paper backing layer, e.g., forabsorbing moisture during a food product preparation or cooking process,or for controlling the amount of steam/moisture within the packaging,etc. It should be noted that the insert 1502 may include or be made upof other materials, such as various sealants, polymer films, etc.,whereas the film 1530 itself may be any suitable material, such asflexible film, semi-rigid polymers, etc. Additionally, insert 1502 mayinclude a plastic backing layer such as a thermoplastic polymer such asoriented polyethylene terephthalate (e.g., a 48 gauge OPET material,etc.) or similar material with an absorbent layer laminated thereon. Forexample, the insert 1502 may include an absorbent layer comprising 60%cellulose and 40% polypropylene laminated on a 48 gauge OPET material.Multiple layers of such plastic backing layers may be used for addedrigidity.

As illustrated in FIG. 47B, the insert 1502, and the food product, notshown, may be inserted, e.g., using a horizontal form fill sealapparatus, into film 1530. The film 1530 may be formed into acylindrical tube or otherwise encompassing shape configured to encloseboth the insert 1502 and the food product. That is, film 1530 and theinsert 1502 may progress through the flow-wrapping apparatus or systemin the direction of arrow 1540. In forming film 1530, an overlappingseal may be created by overlapping seal portions 1532 on either side offilm 1530, and sealing portions 1532 together. Portions 1532 can bemated and sealed to form a flat seal by, e.g., pulling film 1530 andinsert 1502 (as well as a food product supported and enclosed therein)through the aforementioned former or forming area and allowing one ormore seal wheels of the flow-wrapping apparatus of system to sealportions 1532 by way of heat and pressure, or a cold seal, etc.

As discussed above, after forming film 1530 about the insert 1502 andthe food product, two open ends can result, which may be crimped tofully seal the food product within film 1530 and supported by the insert1502, thus allowing the insert 1502 to ultimately sit or rest on abottom of film 1530. The resulting flat seal and/or one or both crimpedends can be created in such a manner that allows for self-venting, aspreviously described. The resulting package could be moisture and/or gasimpermeable.

FIGS. 48A and 48B illustrate an insert 1602 to be contained within afilm 1620. The insert 1602 may include an absorbent layer, a paperlayer, or an absorbent layer laminated on a paper backing (or plasticbacking). The insert 1602 may include a base 1615 only. The base 1615may be designed to support the bottom portion of a food product. Havingthe base 1615 only without any sides may allow both the food product andthe insert 1602 to be easily slid out of an open end of the package, incases where the food product adheres to the base 1615, to fully removeboth the insert 1602 and the food product. Alternatively, having nosides may allow the food product to be easily slid out of an open end ofthe package to fully remove the food product or, alternatively, mayallow the food product to be slid out gradually while one is eating thefood product, while the insert remains at least partially in the film1620 while still absorbing moisture. In this way, the insert 1602 mayalso provide additional stability to both the package, while within thepackage, and to the food product when the insert 1602 and food productare removed from the package.

The film 1620 may be a section of a film roll that can be fed via a filmfeed assembly onto a former or forming area in a flow-wrapping apparatusor system. Film 1620 may or may not include laminated areas, not shown,such as the laminated areas 1304, 1312 or be entirely laminated such asthe film 1318 described above. However, these laminated areas may beomitted since the insert 1602 may be sufficient to absorb any moisturegiven off by the food product during heating.

The insert 1602 may be made up of a lamination of materials, bylaminating an absorbent layer on a paper backing layer, e.g., forabsorbing moisture during a food product preparation or cooking process,or for controlling the amount of steam/moisture within the packaging,etc. It should be noted that the insert 1602 may include or be made upof other materials, such as various sealants, polymer films, etc.,whereas the film 1620 itself may be any suitable material, such asflexible film, semi-rigid polymers, etc. Additionally, insert 1602 mayinclude a plastic backing layer such as a thermoplastic polymer such asoriented polyethylene terephthalate (e.g., a 48 gauge OPET material,etc.) or similar material with an absorbent layer laminated thereon. Forexample, the insert 1602 may include an absorbent layer comprising 60%cellulose and 40% polypropylene laminated on a 48 gauge OPET material.Multiple layers of such plastic backing layers may be used for addedrigidity.

As illustrated in FIG. 48B, the insert 1602, and the food product, notshown, may be inserted, e.g., using a horizontal form fill sealapparatus, into film 1620. The film 1620 may be formed into acylindrical tube or otherwise encompassing shape configured to encloseboth the insert 1602 and the food product. That is, film 1620 and theinsert 1602 may progress through the flow-wrapping apparatus or systemin the direction of arrow 1630. In forming film 1620, a fin seal may becreated by forming fins 1622 on either side of film 1620, and sealingfins 1622 together. Fins 1622 can be mated and sealed to form a fin sealby, e.g., pulling film 1620 and insert 1602 (as well as a food productsupported and enclosed therein) through the aforementioned former orforming area and allowing fin seal wheels of the flow-wrapping apparatusof system to seal fins 1622 by way of heat and pressure, or a cold seal,etc.

As discussed above, after forming film 1620 about the insert 1602 andthe food product, two open ends can result, which may be crimped tofully seal the food product within film 1620 and supported by the insert1602, thus allowing the insert 1602 to ultimately sit or rest on abottom of film 1620. The resulting fin seal and/or one or both crimpedends can be created in such a manner that allows for self-venting, aspreviously described. The resulting package could be moisture and/or gasimpermeable.

FIG. 49 illustrates an alternative package configuration similar to thatshown in FIGS. 46A and 46B. As illustrated in FIG. 49, an insert 1702 isinserted into a film 1720 where the film 1720 includes fins 1722positioned under the insert 1702 rather than above an insert as shown inFIG. 46B. The film 1720 may be a section of a film roll that can be fedvia a film feed assembly onto a former or forming area in aflow-wrapping apparatus or system. Film 1720 may or may not includelaminated areas, not shown, such as the laminated areas 1304, 1312 or beentirely laminated such as the film 1318 described above. However, theselaminated areas may be omitted since the insert 1702 may be sufficientto absorb any moisture given off by the food product during heating.

The insert 1702 may be similar in all or some ways to the insert 1402shown in FIGS. 46A and 46B. As illustrated in FIG. 49, the insert 1702,and the food product, not shown, may be inserted, e.g., using ahorizontal form fill seal apparatus, into film 1720. The film 1720 maybe formed into a cylindrical tube or otherwise encompassing shapeconfigured to enclose both the insert 1702 and the food product. Thatis, film 1720 and the insert 1702 may progress through the flow-wrappingapparatus or system as discussed above. In forming film 1720, a fin sealon a bottom of the package below the food product and the insert 1702may be created by forming fins 1722 on either side of film 1720, andsealing fins 1722 together. Fins 1722 can be mated and sealed to form afin seal by, e.g., pulling film 1720 and insert 1702 (as well as a foodproduct supported and enclosed therein) through the aforementionedformer or forming area and allowing fin seal wheels of the flow-wrappingapparatus of system to seal fins 1722 by way of heat and pressure, or acold seal, etc.

As discussed above, after forming film 1720 about the insert 1702 andfood product, two open ends can result, which may be crimped to fullyseal the food product within film 1720 and supported by the insert 1702.It should be noted that the resulting fin seal can be folded down oragainst film 1720, allowing the insert 1702 to ultimately sit or rest ona bottom of film 1720 including the fin seal. The resulting fin sealand/or one or both crimped ends can be created in such a manner thatallows for self-venting, as previously described. The resulting packagecould be moisture and/or gas impermeable.

FIG. 50 illustrates another alternative package configuration combiningan insert 1802 similar to those in FIGS. 46A, 46B and 49, and a film1820 similar to the film 1530 of FIG. 47B. As illustrated in FIG. 50,the insert 1802 is inserted into the film 1820 where the film 1820includes seal portions 1832 positioned under the insert 1802 rather thanabove an insert as shown in FIG. 47B. The film 1820 may be a section ofa film roll that can be fed via a film feed assembly onto a former orforming area in a flow-wrapping apparatus or system. Film 1820 may ormay not include laminated areas, not shown, such as the laminated areas1304, 1312 or be entirely laminated such as the film 1318 describedabove. However, these laminated areas may be omitted since the insert1802 may be sufficient to absorb any moisture given off by the foodproduct during heating.

The insert 1802 may be similar in all or some ways to the insert 1402shown in FIGS. 46A and 46B. As illustrated in FIG. 50 the insert 1802,and the food product, not shown, may be inserted, e.g., using ahorizontal form fill seal apparatus, into film 1820. The film 1820 maybe formed into a cylindrical tube or otherwise encompassing shapeconfigured to enclose both the insert 1802 and the food product. Thatis, film 1820 and the insert 1802 may progress through the flow-wrappingapparatus or system. In forming film 1820, an overlapping seal may becreated on a bottom of the package under the food product and the insert1802 by overlapping seal portions 1832 on either side of film 1820, andsealing portions 1832 together. Portions 1832 can be mated and sealed toform a flat seal by, e.g., pulling film 1820 and insert 1802 (as well asa food product supported and enclosed therein) through theaforementioned former or forming area and allowing one or more sealwheels of the flow-wrapping apparatus of system to seal portions 1832 byway of heat and pressure, or a cold seal, etc.

As discussed above, after forming film 1820 about the insert 1802 andthe food product, two open ends can result, which may be crimped tofully seal the food product within film 1820 and supported by the insert1802, thus allowing the insert 1802 to ultimately sit or rest on abottom of film 1820 that includes the seal portions 1832. The resultingflat seal and/or one or both crimped ends can be created in such amanner that allows for self-venting, as previously described. Theresulting package could be moisture and/or gas impermeable.

FIG. 51 illustrates yet another alternative package configuration. Thepackage of FIG. 51 includes a fin seal film 1920 similar to the films1420 of FIG. 46B, 1620 of 48B and 1720 of FIG. 49. The package of FIG.51 also includes a four-sided insert 1902 similar to the insert 1502 ofFIGS. 47A and 47B. As illustrated in FIG. 51, the insert 1902 isinserted into the film 1920 where the film 1920 includes fins 1922positioned under the insert 1902. The film 1920 may be a section of afilm roll that can be fed via a film feed assembly onto a former orforming area in a flow-wrapping apparatus or system. Film 1920 may ormay not include laminated areas, not shown, such as the laminated areas1304, 1312 or be entirely laminated such as the film 1318 describedabove. However, these laminated areas may be omitted since the insert1902 may be sufficient to absorb any moisture given off by the foodproduct during heating.

As illustrated in FIG. 51, the film 1920 may include a steam valve 1940formed in the film 1920. The steam valve 1940 may be a self-ventingvalve that releases pressure after the package pressure reaches athreshold level during heating. The steam valve 1940 may be configuredto release pressure, but retain moisture in the package, while thecooking continues. This may result in some food products retaining somemoisture and remaining soft rather than drying out and becoming hardand/or brittle. For example, a food product such as a tortilla, bread,roll, breading or others, may benefit from such a steam valve. The steamvalve 1940 may be an actual mechanical valve attached to the film 1920or, alternatively, may be formed in the film 1920 using amicro-perforation and/or micro-scoring technique to form a mechanicalself-venting aperture in the film 1920. In this way, the film 1920 andthe package can remain moisture and/or gas impermeable prior to thesteam vent releasing. The steam valve 1940 of FIG. 51 is circular orelliptical in shape, but other shaped valves may also be utilized. Inaddition, multiple steam valves 1940 may be included in the film 1920.

The insert 1902 may be similar in all or some ways to the insert 1502shown in FIGS. 47A and 47B. As illustrated in FIG. 51, the insert 1902,and the food product, not shown, may be inserted, e.g., using ahorizontal form fill seal apparatus, into film 1920. The film 1920 maybe formed into a cylindrical tube or otherwise encompassing shapeconfigured to enclose both the insert 1902 and the food product. Thatis, film 1920 and the insert 1902 may progress through the flow-wrappingapparatus or system as discussed above. In forming film 1920, a fin sealon a bottom of the package below the food product and the insert 1902may be created by forming the fins 1922 on either side of film 1920, andsealing the fins 1922 together. Fins 1922 can be mated and sealed toform a fin seal by, e.g., pulling film 1920 and insert 1902 (as well asa food product supported and enclosed therein) through theaforementioned former or forming area and allowing fin seal wheels ofthe flow-wrapping apparatus of system to seal fins 1922 by way of heatand pressure, or a cold seal, etc.

As discussed above, after forming film 1920 about the insert 1902 andfood product, two open ends can result, which may be crimped to fullyseal the food product within film 1920 and supported by the insert 1902.It should be noted that the resulting fin seal can be folded down oragainst film 1920, allowing the insert 1902 to ultimately sit or rest ona bottom of film 1920 and the fins 1922. The resulting fin seal and/orone or both crimped ends can be created in such a manner that allows forself-venting, as previously described. However, due to the presence ofthe steam valve 1940, self-venting seals may not be necessary ordesired, depending on the situation.

FIG. 52 illustrates yet another alternative package configuration. Thepackage of FIG. 52 includes an overlapping seal film 2020 similar to thefilms 1530 of FIG. 47B, and 1820 of FIG. 50. The package of FIG. 52 alsoincludes a two-sided insert 2002 similar to the inserts 1402 of FIGS.46A and 46B, 1702 of FIGS. 49 and 1802 of FIG. 50. As illustrated inFIG. 52, the insert 2002 is inserted into the film 2020 where the film2020 includes seal portions 2032 positioned under the insert 2002. Thefilm 2020 may be a section of a film roll that can be fed via a filmfeed assembly onto a former or forming area in a flow-wrapping apparatusor system. Film 2020 may or may not include laminated areas, not shown,such as the laminated areas 1304, 1312 or be entirely laminated such asthe film 1318 described above. However, these laminated areas may beomitted since the insert 2002 may be sufficient to absorb any moisturegiven off by the food product during heating.

As illustrated in FIG. 52, the film 2020 may include a steam valve strip2040 formed in the film 2020 generally parallel to a length of thepackage. The steam valve strip 2040 may be a self-venting valve thatreleases pressure after the package pressure reaches a threshold levelduring heating. The steam valve strip 2040 may be configured to releasepressure, but retain moisture in the package while the cookingcontinues. This may result in some food products retaining some moistureand remaining soft rather than drying out and becoming hard and/orbrittle. For example, a food product such as a tortilla, bread, roll,breading or others, may benefit from such a steam vent. The steam valvestrip 2040 may be an actual mechanical strip valve attached to the film2020 or, alternatively, may be formed in the film 2020 using amicro-perforation and/or micro-scoring technique to form a mechanicalself-venting aperture in the film 2020. In this way, the film 2020 andthe package may remain moisture and/or gas impermeable prior to thesteam vent releasing. The steam valve strip 2040 of FIG. 52 is straight,but other shaped strip valves may also be utilized. In addition,multiple steam valve strips 2040 may be included in the film 2020.

The insert 2002 may be similar in all or some ways to the insert 1402shown in FIGS. 46A and 46B. As illustrated in FIG. 52, the insert 2002,and the food product, not shown, may be inserted, e.g., using ahorizontal form fill seal apparatus, into film 2020. The film 2020 maybe formed into a cylindrical tube or otherwise encompassing shapeconfigured to enclose both the insert 2002 and the food product. Thatis, film 2020 and the insert 2002 may progress through the flow-wrappingapparatus or system as discussed above. In forming film 2020, anoverlapping seal may be created on a bottom of the package under thefood product and the insert 2002 by overlapping the seal portions 2032on either side of film 2020, and sealing portions 2032 together.Portions 2032 can be mated and sealed to form a flat seal by, e.g.,pulling film 2020 and insert 2002 (as well as a food product supportedand enclosed therein) through the aforementioned former or forming areaand allowing one or more seal wheels of the flow-wrapping apparatus ofsystem to seal portions 2032 by way of heat and pressure, or a coldseal, etc.

As discussed above, after forming film 2020 about the insert 2002 andthe food product, two open ends can result, which may be crimped tofully seal the food product within film 2020 and supported by the insert2002, thus allowing the insert 2002 to ultimately sit or rest on abottom of film 2020 that includes the seal portions 2032. The resultingflat seal and/or one or both crimped ends can be created in such amanner that allows for self-venting, as previously described. Theresulting package could be moisture and/or gas impermeable. However, dueto the presence of the steam valve 2040, self-venting seals may not benecessary or desired, depending on the situation.

FIG. 53 illustrates yet another alternative package configuration. Thepackage of FIG. 53 includes a fin seal film 2120 similar to the films1420 of FIG. 46B, 1620 of 48B, 1720 of FIGS. 49 and 1920 of FIG. 51. Thepackage of FIG. 53 also includes a sideless insert 2102 similar to theinsert 1602 of FIGS. 48A and 48B. As illustrated in FIG. 53, the insert2102 is inserted into the film 2120 where the film 2120 includes fins2122 positioned above the insert 2102. The film 2120 may be a section ofa film roll that can be fed via a film feed assembly onto a former orforming area in a flow-wrapping apparatus or system. Film 2120 may ormay not include laminated areas, not shown, such as the laminated areas1304, 1312 or be entirely laminated such as the film 1318 describedabove. However, these laminated areas may be omitted since the insert2102 may be sufficient to absorb any moisture given off by the foodproduct during heating.

As illustrated in FIG. 53, the film 2120 may include two steam valvestrips 2140 formed on opposite sides of the film 1920 generally parallelto a length of the package. The steam valve strips 2140 may be aself-venting valve that releases pressure after the package pressurereaches a threshold level during heating. The steam valve strips 2140may be configured to release pressure, but retain moisture in thepackage, while the cooking continues. This may result in some foodproducts retaining some moisture and remaining soft rather than dryingout and becoming hard and/or brittle. For example, a food product suchas a tortilla, bread, roll, breading or others, may benefit from such asteam valve. The steam valve strips 2140 may be actual mechanical valvesattached to the film 2120 or, alternatively, may be formed in the film2120 using a micro-perforation and/or micro-scoring technique to form amechanical self-venting aperture in the film 2120. In this way, the film2120 and the package can remain moisture and/or gas impermeable prior tothe steam vent releasing. The steam valve strips 2140 of FIG. 53 arestraight, but other shaped strips valves may also be utilized.

The insert 2102 may be similar in all or some ways to the insert 1602shown in FIGS. 48A and 48B. As illustrated in FIG. 53, the insert 2102,and the food product, not shown, may be inserted, e.g., using ahorizontal form fill seal apparatus, into film 2120. The film 2120 maybe formed into a cylindrical tube or otherwise encompassing shapeconfigured to enclose both the insert 2102 and the food product. Thatis, film 2120 and the insert 2102 may progress through the flow-wrappingapparatus or system as discussed above. In forming film 2120, a fin sealon a top of the package above the food product and the insert 2102 maybe created by forming the fins 2122 on either side of film 2120, andsealing the fins 2122 together. Fins 2122 can be mated and sealed toform a fin seal by, e.g., pulling film 2120 and insert 2102 (as well asa food product supported and enclosed therein) through theaforementioned former or forming area and allowing fin seal wheels ofthe flow-wrapping apparatus of system to seal fins 2122 by way of heatand pressure, or a cold seal, etc.

As discussed above, after forming film 2120 about the insert 2102 andfood product, two open ends can result, which may be crimped to fullyseal the food product within film 2120 and supported by the insert 2102.It should be noted that the resulting fin seal can be folded down oragainst film 2120, allowing the insert 2102 to ultimately sit or rest ona bottom of film 2120. The resulting fin seal and/or one or both crimpedends can be created in such a manner that allows for self-venting, aspreviously described. However, due to the presence of the steam valvestrips 2140, self-venting seals may not be necessary or desired,depending on the situation.

FIG. 54 illustrates yet another alternative package configuration. Thepackage of FIG. 54 includes an overlapping seal film 2220 similar to thefilms 1530 of FIG. 47B, 1820 of FIGS. 50 and 2020 of FIG. 52. Thepackage of FIG. 54 also includes a two-sided insert 2202 similar to theinserts 1402 of FIGS. 46A and 46B, 1702 of FIG. 49, 1802 of FIGS. 50 and2002 of FIG. 52. As illustrated in FIG. 54, the insert 2202 is insertedinto the film 2220 where the film 2220 includes seal portions 2232positioned under the insert 2202. The film 2220 may be a section of afilm roll that can be fed via a film feed assembly onto a former orforming area in a flow-wrapping apparatus or system. Film 2220 may ormay not include laminated areas, not shown, such as the laminated areas1304, 1312 or be entirely laminated such as the film 1318 describedabove. However, these laminated areas may be omitted since the insert2202 may be sufficient to absorb any moisture given off by the foodproduct during heating.

As illustrated in FIG. 54, the film 2220 may include a steam valve strip2240 formed in the film 2220 generally perpendicular to a length of thepackage. The steam valve strip 2240 may be a self-venting valve thatreleases pressure after the package pressure reaches a threshold levelduring heating. The steam valve strip 2240 may be configured to releasepressure, but retain moisture in the package while the cookingcontinues. This may result in some food products retaining some moistureand remaining soft rather than drying out and becoming hard and/orbrittle. For example, a food product such as a tortilla, bread, roll,breading or others, may benefit from such a steam vent. The steam valvestrip 2240 may be an actual mechanical strip valve attached to the film2220 or, alternatively, may be formed in the film 2220 using amicro-perforation and/or micro-scoring technique to form a mechanicalself-venting aperture in the film 2220. In this way, the film 2220 andthe package may remain moisture and/or gas impermeable prior to thesteam vent releasing. The steam valve strip 2240 of FIG. 54 is straight,but other shaped strip valves may also be utilized. In addition,multiple steam valve strips 2240 may be included in the film 2220.

The insert 2202 may be similar in all or some ways to the insert 1402shown in FIGS. 46A and 46B. As illustrated in FIG. 54, the insert 2202,and the food product, not shown, may be inserted, e.g., using ahorizontal form fill seal apparatus, into film 2220. The film 2220 maybe formed into a cylindrical tube or otherwise encompassing shapeconfigured to enclose both the insert 2202 and the food product. Thatis, film 2220 and the insert 2202 may progress through the flow-wrappingapparatus or system as discussed above. In forming film 2220, anoverlapping seal may be created on a bottom of the package under thefood product and the insert 2202 by overlapping the seal portions 2232on either side of film 2220, and sealing portions 2232 together.Portions 2232 can be mated and sealed to form a flat seal by, e.g.,pulling film 2220 and insert 2202 (as well as a food product supportedand enclosed therein) through the aforementioned former or forming areaand allowing one or more seal wheels of the flow-wrapping apparatus ofsystem to seal portions 2232 by way of heat and pressure, or a coldseal, etc.

As discussed above, after forming film 2220 about the insert 2202 andthe food product, two open ends can result, which may be crimped tofully seal the food product within film 2220 and supported by the insert2202, thus allowing the insert 2202 to ultimately sit or rest on abottom of film 2220 that includes the seal portions 2232. The resultingflat seal and/or one or both crimped ends can be created in such amanner that allows for self-venting, as previously described. Theresulting package could be moisture and/or gas impermeable. However, dueto the presence of the steam valve strip 2240, self-venting seals maynot be necessary or desired, depending on the situation.

It should be noted that the various embodiments of inserts illustratedin FIGS. 46-54, and described herein, may incorporate different shapesand/or include different numbers of sides extending upward from a baseof the inserts so as to accommodate differently shaped food products.For example, an insert could be triangular, square, circular,pentagonal, hexagonal, or any other shape. It should be further notedthat the various embodiments illustrated in FIGS. 46-54 and describedherein, and implemented utilizing an insert within a single, e.g.,flow-wrap film, may incorporate one or more features of otherembodiments illustrated in FIGS. 1-45 and described above.

The various embodiments of the packaged food product and packagingdisclosed herein provide many benefits to consumers. For example, thepackaged food product provides an “on-the-go” food product havinguser-friendly packaging requiring only a “single step” heating in amicrowave oven. Control of steam and moisture content within thepackaging during heating decreases preparation time, provides foroptimal moisture content of the food product, and ensures an evenlyheated food product. Further, the anti-fog treatment of the packagingreduces water droplet formation and maintains an aesthetically pleasingappearance for consumers. Further yet, because the food product may beheated without needing to open the packaging, no additional materialsare required (e.g., a napkin, paper towel, etc.), no messes are madewithin the microwave (e.g., due to spills, splattering, melting, etc.resulting from unpackaged food products or open packagings), and thefood product may be eaten right out of the packaging after heating. Thecreation of a “steam dome” assists in both faster cooking and providingan easy peel feature by weakening the seal through the escape of steam.

Furthermore, it should be noted that while in various embodimentsspecific dimensions have been provided, such dimensions are not limitingsuch that the embodiments disclosed herein may be usable with a varietyof dimensions not specified herein (e.g., such as the width of a seal ofseal portion, the length and/or width of a vent portion, etc. Further,the number, size, spacing, and shape of various features may also bevaried from the specific embodiments shown herein (e.g., the shape of aseal or seal portion, vent, of peelable corner portion, etc.). Forexample, in some embodiments, one, some, or all corners of a packagingmay provide an “easy-peal” feature. Further, reliefs formed into sealbars usable to form vent portions may varying dimensions for length,width, and depth. For example, while the “depth of the relief is shownin some embodiments as being 0.010 inches, according to various otherembodiments, the depth of the relief may be more or less than 0.010inches (e.g., 0.005 inches, 0.003 inches, 0.015 inches, etc.). All suchvariations in the size shape, number, positioning, etc. of the variouscomponents and features disclosed herein are within the scope of thepresent disclosure.

It is important to note that the construction and arrangement of theelements of the products and methods as shown in the exemplaryembodiments are illustrative only. Although only a few embodiments havebeen described in detail in this disclosure, those skilled in the artwho review this disclosure will readily appreciate that manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, materials, colors, orientations,etc.) without materially departing from the novel teachings andadvantages of the subject matter recited in the various embodiments.Accordingly, all such modifications are intended to be included withinthe scope of the present disclosure as defined in the appended claims.The order or sequence of any process or method steps may be varied orre-sequenced according to alternative embodiments. Other substitutions,modifications, changes, and/or omissions may be made in the design,operating conditions, and arrangement of the exemplary embodimentswithout departing from the spirit of the present disclosure.

What is claimed is:
 1. A package, comprising: a sheet of film formableabout a food product; and an insert configured to support the foodproduct, the insert comprising an absorbent material; wherein a firstedge and a second edge of the sheet of film are sealed together creatingan enclosure for the food product and the insert.
 2. The package ofclaim 1, wherein the insert comprises a backing material and theabsorbent material is laminated to at least one area of the backingmaterial.
 3. The package of claim 2, wherein the backing material ispaper board.
 4. The package of claim 1, wherein a third edge and afourth edge of the sheet of film are each sealed via respective crimpedseals.
 5. The package of claim 4, wherein the sealed first and secondedges are positioned under a bottom surface of the insert opposite a topsurface of the insert that supports the food product.
 6. The package ofclaim 1, further comprising at least one steam vent formed in the sheetof film.
 7. The package of claim 6, wherein the at least one steam ventcomprises micro-scores or micro-perforations configured to mechanicallyvent pressure from the package while being heated.
 8. The package ofclaim 4, wherein at least one of the respective crimped seals isconfigured to be self-venting.
 9. The package of claim 1, wherein theinsert comprises a base and at least two sides extending up from thebase to contain the food product in one direction.
 10. The package ofclaim 9, wherein the insert comprises at least four sides extending upfrom the base to contain the food product in two directions.
 11. Thepackage of claim 1, wherein a surface of the film comprises at least oneof an anti-fog feature and a steam dome feature.
 12. The package ofclaim 4, wherein the first edge and the second edge are sealed via acrimp seal.
 13. The package of claim 12, wherein the first edge and thesecond edge are sealed via a self-venting fin seal.
 14. The package ofclaim 4, wherein the first edge and the second edge are sealed togethervia an overlapping flat seal.
 15. The package of claim 4, wherein thepackage is moisture and gas impermeable.
 16. A packaged food productcomprising: a food product; and a package having an interior areacontaining the food product, the package comprising: a sheet of filmformable about a food product; and an insert configured to support thefood product, the insert comprising an absorbent material; wherein afirst edge and a second edge of the sheet of film are sealed togethercreating an enclosure for the food product and the insert.
 17. Thepackaged food product of claim 16, wherein the insert comprises abacking material and the absorbent material is laminated to at least onearea of the backing material.
 18. The packaged food product of claim 16,further comprising at least one steam vent formed in the sheet of film.19. The packaged food product of claim 18, wherein the at least onesteam vent comprises micro-scores or micro-perforations configured tomechanically vent pressure from the package while being heated.
 20. Thepackaged food product of claim 16, wherein the insert comprises a baseand at least two sides extending up from the base to contain the foodproduct in one direction.